Systems and methods for achieving peak ion energy enhancement with a low angular spread

ABSTRACT

Systems and methods for increasing peak ion energy with a low angular spread of ions are described. In one of the systems, multiple radio frequency (RF) generators that are coupled to an upper electrode associated with a plasma chamber are operated in two different states, such as two different frequency levels, for pulsing of the RF generators. The pulsing of the RF generators facilitates a transfer of ion energy during one of the states to another one of the states for increasing ion energy during the other state to further increase a rate of processing a substrate.

CLAIM OF PRIORITY

This application is a continuation of and claims the benefit of andpriority, under 35 U.S.C. §120, to U.S. Pat. Application No. 17/347,504,filed on Jun. 14, 2021, and titled “SYSTEMS AND METHODS FOR ACHIEVINGPEAK ION ENERGY ENHANCEMENT WITH A LOW ANGULAR SPREAD”, which is acontinuation of and claims the benefit of and priority, under 35 U.S.C.§120, to U.S. Pat. Application No. 16/533,150, filed on Aug. 6, 2019,titled “SYSTEMS AND METHODS FOR ACHIEVING PEAK ION ENERGY ENHANCEMENTWITH A LOW ANGULAR SPREAD”, and issued as U.S. Pat. No. 11,049,693,which is a continuation of and claims the benefit of and priority, under35 U.S.C. §120, to U.S. Pat. Application No. 15/693,134, filed on Aug.31, 2017, titled “SYSTEMS AND METHODS FOR ACHIEVING PEAK ION ENERGYENHANCEMENT WITH A LOW ANGULAR SPREAD”, and issued as U.S. Pat. No.10,395,894, all of which are hereby incorporated by reference in theirentirety.

FIELD

The present embodiments relate to systems and methods for achieving peakion energy enhancement with a low angular spread.

BACKGROUND

In some plasma processing systems, a radio frequency (RF) signal isprovided to an electrode within a plasma chamber. The RF signal is usedto generate plasma within the plasma chamber. The plasma is used for avariety of operations, e.g., clean substrate placed on a lowerelectrode, etch a substrate, etc. During processing of the substrateusing the plasma, the RF signal is continuous.

It is in this context that embodiments described in the presentdisclosure arise.

SUMMARY

Embodiments of the disclosure provide systems, apparatus, methods andcomputer programs for achieving peak ion energy enhancement with a lowangular spread. It should be appreciated that the present embodimentscan be implemented in numerous ways, e.g., a process, an apparatus, asystem, a device, or a method on a computer readable medium. Severalembodiments are described below.

In some embodiments, the systems and methods described herein enhancesion energy without increasing or substantially increasing radiofrequency (RF) bias voltage or RF bias power that is supplied andproduces a narrow angular spread at peak energy. The narrow angularspread at the peak energy is used for achieving high aspect ratioetching.

The systems and methods described herein apply a high frequency leveland a low frequency level during a pulsing time period. The highfrequency level is applied by a high frequency RF generator, such as a27 megahertz RF generator or a 60 megahertz RF generator, and the lowfrequency level is applied by another low frequency RF generator, suchas a 2 megahertz RF generator or a 13.56 megahertz RF generator or a 400kilohertz RF generator. The systems and methods has an advantage offacilitating a tight, such as a narrow, ion angle with an increase inpeak ion energy, such as by greater than 35%, compared to a peak ionenergy achieved with nonpulsing of an RF signal, such as a continuouswave RF signal. The tight ion angle and the increase in the peak ionenergy are achieved as a result of low frequency and high frequencysynchronized RF voltage pulses. During an onset of the high frequencylevel, plasma ions receive a voltage boost from a previous, such as apreceding, low frequency level. For example, an amount of voltage fromthe low frequency level is added to an amount of voltage to the highfrequency level that is consecutive to the low frequency level. Thiscauses higher peak energy in an ion energy and angular distributionfunction (IEADF) for the systems and methods described herein comparedto continuous wave technology for the same RF bias voltage. A sheathvoltage of a plasma sheath charges and discharges based an equation (1),which is provided below.

$V_{High\_ Peak} = V_{High} + V_{Low}\exp( \frac{- t}{RC} )$

where V_(Low) is a voltage level of an RF signal having the lowfrequency level, V_(High) is the voltage level of a RF signal having thehigh frequency level, V_(High_Peak) is a final voltage level after timet of the transition between low to high frequency level wherecontribution of previous low frequency level is added to the currenthigh frequency voltage level Moreover, in the equation (1), exp is anexponential function, R is a resistance at an output of the plasmasheath that acts as a capacitor, RC is the time constant of thecapacitor, and C is a capacitance of the capacitor. During the onset ofthe high frequency level, plasma ions travel through the plasma sheathand strike a substrate with a higher voltage compared to the continuouswave technology because of a voltage level from the previous lowfrequency level. The voltage level from the previous low frequency levelis added to a voltage level of the high frequency level. This increasein the plasma sheath voltage level increases a denominator in anequation (2), which is provided below.

$\sigma_{\theta} = \tan^{- 1}( \sqrt{\frac{T_{i}}{eV_{s}}} )$

where V_(s) is a voltage of the plasma sheath, T_(i) is the iontemperature at sheath edge, e is the amount of charge carried by asingle electron, and tan is a tangent function. The increase in thedenominator of equation (2) provides the narrower ion angle σ_(θ). Also,the low frequency level increases the resistance R and the increase inthe resistance R increases the time constant RC. When the time constantRC increases during the low frequency level, a bias voltage at thesubstrate is enhanced even more compared to when a single frequency isused without pulsing, e.g., in a continuous wave mode. The pulsingbetween the high and low frequency levels together produce apre-determined amount, such as 35-50%, of enhancement in an etch rateand a pre-determined amount, such as 10%, improvement in a criticaldimension of the channel compared to a system in which the bias voltageat the substrate is increased by increasing a bias voltage that issupplied by a bias RF generator system. The improvement in the criticaldimension is achieved when there is straighter etched feature.

In addition, the systems and methods described herein enhances ionenergy without substantially increasing the bias voltage or bias powerand generates a narrow angular spread at peak energy by contributing anamount of power or voltage from a low power parameter level to an amountof power of a high power parameter level. The systems and methodsdescribed herein employ a high power parameter level during a high stateand a low power parameter level during a low state of a pulsing period.The low power parameter level is a percentage of a level of the powerparameter during the high state. The high power parameter level and thelow power parameter level are supplied by the same RF generator, such asthe high frequency RF generator or the low frequency RF generator. Assuch, during the onset of the high state, the plasma sheath that acts asthe capacitor holds a previous low voltage or power of the low powerparameter level, which is then added to a high voltage or high power ofthe high power parameter level to cause a higher peak energy in IEADF.The peak energy is higher during the high state and the low statecompared to the continuous wave technology for the same bias voltage. Avoltage of the plasma sheath charges and discharges based on theequation (1).

During the onset of the high power parameter level, the plasma ionstravel through the plasma sheath and strikes the substrate with a highervoltage compared to the continuous wave technology. An amount of voltageor power from a previous, such as a preceding, low power parameter leveladds a contribution to the voltage of the high power parameter level.The addition to the voltage of the high power parameter level increasesa voltage of the plasma sheath to further increase the denominator ofthe equation (2). The increase in the denominator of the equation (2)results in a narrow ion angle. Also, unlike the continuous wavetechnology, since during a transition from the low power parameter levelto the high power parameter level, the plasma sheath is initiallythinner, the plasma ions go through less collisions and less scatteringto preserve both ion energy and tighter ion angle. The collisions andscattering are less compared to a thicker sheath of in the continuouswave mode. This energy enhanced ions at peak energy during the highpower parameter level maintain a tighter ion angle used for high aspectratio etching compared to that for the continuous wave mode. Also, sinceduring the low power parameter level ion temperature Ti at sheath edgeis low, during the transition from the low power parameter level to thehigh power parameter level the ion angular spread is narrower comparedto CW technology. All these factors together enhance peak energy in theIEDF and tightens ion angle at this peak energy. Moreover, due to thepulsing between the low power parameter level and the high powerparameter level, a mask is eroded less aggressively compared to that inthe continuous wave technology.

In some embodiments, a method for operating a plasma chamber to increaseion energy and decrease angular spread of ions directed towards asurface of a substrate during an etch operation is described. The methodincludes receiving a pulsed signal to drive operation of the plasmachamber. The pulsed signal has two states including a first state and asecond state. The method further includes operating a primary RFgenerator at a primary frequency level during the first state andmaintaining the primary RF generator in an off state during the secondstate. The operation of the primary RF generator during the first stateproduces an increased charge for a plasma sheath formed over thesubstrate. The increased charge adds to a thickness of the plasmasheath. The method also includes operating a secondary RF generator at asecondary frequency level during the second state and maintaining thesecondary RF generator in the off state during the first state. Theoperation of the secondary RF generator during the second state uses atleast part of the increased charge of the plasma sheath produced duringthe first state as additive power to enhance the ion energy generatedduring the second state. The additive power reduces the angular spreadof the ions when directed towards the surface of the substrate. Theprimary and secondary RF generators are coupled via an impedancematching circuit to a top electrode associated with the plasma chamber.The method includes continuing to operate the primary and secondary RFgenerators in the first and second states according to the pulsed signalto enhance the etch operation over multiple cycles of the first andsecond states.

In various embodiments, a method for operating a plasma chamber toincrease ion energy and decrease angular spread of ions directed towardsa surface of a substrate during an etch operation is described. Themethod includes receiving a pulsed signal to drive operation of theplasma chamber. The method further includes operating a primary RFgenerator at a first primary frequency level during the first state anda second primary frequency level during the second state. The operationof the primary RF generator during the first state produces an increasedcharge for a plasma sheath formed over the substrate. The method furtherincludes operating a secondary RF generator at a first secondaryfrequency level during the first state and a second secondary frequencylevel during the second state. The operation of the secondary RFgenerator during the second state uses at least part of the increasedcharge of the plasma sheath produced during the first state as additivepower to enhance the ion energy generated during the second state. Eachof the first primary frequency level, the second primary frequencylevel, the first secondary frequency level, and the second secondaryfrequency level is non-zeo. For example, none of the primary andsecondary RF generators are off during the first and second states. Themethod includes continuing to operate the primary and secondary RFgenerators in the first and second states according to the pulsed signalto enhance the etch operation over multiple cycles of the first andsecond states.

In several embodiments, a system for operating a plasma chamber toincrease ion energy and decrease angular spread of ions directed towardsa surface of a substrate during an etch operation is described. Thesystem includes a primary RF generator having a primary power supplythat generates a primary RF signal. The system further includes asecondary RF generator having a secondary power supply that generates asecondary RF signal. The system also includes an impedance matchingnetwork coupled to the primary power supply and the secondary powersupply. The impedance matching network receives the primary RF signaland the secondary RF signal to generate a modified RF signal. The systemincludes a plasma chamber having a top electrode coupled to theimpedance matching network. The plasma chamber receives the modified RFsignal. The primary RF generator includes one or more processors. Theone or more processors of the primary RF generator receive a pulsedsignal to drive operation of the plasma chamber. The one or moreprocessors operate the primary RF generator at a primary frequency levelduring the first state and maintain the primary RF generator in an offstate during the second state. The operation of the primary RF generatorduring the first state produces an increased charge for a plasma sheathformed over the substrate. The increased charge adds to a thickness ofthe plasma sheath. The secondary RF generator includes one or moreprocessors configured to receive the pulsed signal. The one or moreprocessors of the secondary RF generator operate the secondary RFgenerator at a secondary frequency level during the second state andmaintain the secondary RF generator in the off state during the firststate. The operation of the secondary RF generator during the secondstate uses at least part of the increased charge of the plasma sheathproduced during the first state as additive power to enhance the ionenergy generated during the second state. The additive power reduces theangular spread of the ions when directed towards the surface of thesubstrate. The primary and secondary RF generators continue operation inthe first and second states according to the pulsed signal to enhancethe etch operation over multiple cycles of the first and second states.

Other aspects will become apparent from the following detaileddescription, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments may best be understood by reference to the followingdescription taken in conjunction with the accompanying drawings.

FIG. 1A is a block diagram of an embodiment of a plasma tool toillustrate frequency level two-state pulsing for achieving peak ionenergy enhancement with a low angular spread.

FIG. 1B is a diagram of embodiments of graphs to illustrate thefrequency level two-state pulsing in which one state is an off state.

FIG. 1C is a diagram of embodiments of graphs to illustrate thefrequency level two-state pulsing in which both states are non-zerostates.

FIG. 2A is a block diagram of an embodiment of a plasma tool toillustrate frequency level three-state pulsing for achieving peak ionenergy enhancement with a low angular spread.

FIG. 2B is a diagram of embodiments of graphs to illustrate thefrequency level three-state pulsing.

FIG. 2C is a diagram of embodiments of graphs to illustrate thefrequency level three-state pulsing.

FIG. 2D is a diagram of embodiments of graphs to illustrate thefrequency level three-state pulsing.

FIG. 2E is a diagram of embodiments of graphs to illustrate thefrequency level three-state pulsing.

FIG. 3 is a diagram of embodiments of multiple graphs to illustrate thatwith pulsing of frequency level of an RF signal generated by a frequencypulsed RF generator, there is an increase in peak energy of plasma ionsthat are incident on a surface of a substrate.

FIG. 4 is a diagram of an embodiment of a graph to illustrate that withan increase in a bias voltage that is supplied by a bias RF generator,there is a decrease in an angular distribution of plasma ions.

FIG. 5 is a diagram of an embodiment of a graph to illustrate that anangular spread that is comparable to that achieved with the increase inthe bias voltage is achieved by pulsing a frequency level of an RFgenerator.

FIG. 6 is a diagram of embodiments of graphs to illustrate a differencein a critical dimension (CD) of a channel formed within the substrate.

FIG. 7A is a block diagram of an embodiment of a plasma tool toillustrate power parameter level pulsing for achieving peak ion energyenhancement with a low angular spread.

FIG. 7B is a diagram of embodiments of graphs to illustrate pulsing of apower parameter of an RF signal generated by an RF generator of theplasma tool of FIG. 7A.

FIG. 8 is a diagram of embodiments of multiple graphs to illustrate thatwith an increase in the bias voltage, there is an increase in verticaldirectionality of plasma ions.

FIG. 9 is a diagram of embodiments of multiple graphs to illustrate thatwith pulsing of a power parameter level of an RF signal generated by anRF generator, there is an increase in peak energy of plasma ions thatare incident on a surface of the substrate.

FIG. 10 is a diagram of an embodiment of the graph of FIG. 4 .

FIG. 11 is a diagram of an embodiment of a graph to illustrate that anangular spread that is comparable to that achieved with the increase inthe bias voltage is achieved by pulsing a power parameter level of an RFgenerator.

FIG. 12 is a diagram of embodiments of graphs to illustrate a differencein the critical dimension achieved between pulsing the power parameterlevel and applying a continuous wave mode.

FIG. 13A is a block diagram of an embodiment of a plasma tool toillustrate power parameter level pulsing of a bias RF generator forachieving peak ion energy enhancement with a low angular spread.

FIG. 13B is a diagram of embodiments of graphs to illustrate pulsing ofa power parameter of an RF signal generated by the bias RF generator ofFIG. 13A.

DETAILED DESCRIPTION

The following embodiments describe systems and methods for achievingpeak ion energy enhancement with a low angular spread. It will beapparent that the present embodiments may be practiced without some orall of these specific details. In other instances, well known processoperations have not been described in detail in order not tounnecessarily obscure the present embodiments.

FIG. 1A is a block diagram of an embodiment of a plasma tool 100 forachieving peak ion energy enhancement with a low angular spread. Theplasma tool 100 includes a radio frequency (RF) generator RFGx, anotherRF generator RFGy, a host computer 116, an impedance matching network(IMN) 104, a plasma chamber 108, another IMN 112, and a bias RFgenerator system 114, which includes one or more bias RF generators. Theplasma tool 100 further includes an RF cable system 137 that couples theRF generator system 114 to the IMN 112 and an RF transmission line 139that couples the IMN 112 to a chuck 110 of the plasma chamber 108. TheRF transmission line 139 includes a metal rod that is surrounded by aninsulator that is further surrounded by a sheath. The metal rod iscoupled to a cylinder via an RF strap and the cylinder is coupled to thechuck 110. Examples of the RF generator RFGx include a low frequency RFgenerator, such as a 400 kilohertz (kHz) RF generator, or a 2 megahertz(MHz) RF generator, or a 13.56 MHz RF generator. Examples of the RFgenerator RFGy include a high frequency RF generator, such as a 13.56MHz, or a 27 MHz, or a 60 MHz RF generator. The RF generator RFGyoperates at a higher frequency than the RF generator RFGx. Examples ofthe host computer 116 include a desktop computer, or a laptop computer,or a smartphone, or a tablet, etc.

The RF cable system 137 includes one or more RF cables that couple thebias RF generator system 114 with the IMN 112. In case multiple RFcables are included within the RF cable system 137, the RF cables arecoupled to different inputs of the IMN 112. For example, one RF cablecouples an output of an RF generator of the bias RF generator system 114with an input of the IMN 112 and another RF cable couples an output ofanother RF generator of the bias RF generator system 114 with anotherinput of the IMN 112.

The IMN 112 includes electric circuit components, e.g., inductors,capacitors, resistors, or a combination of two or more thereof, etc. tomatch an impedance of a load coupled to an output of the IMN 112 with animpedance of a source coupled to one or more inputs of the IMN 112. Forexample, the IMN 112 matches an impedance of the plasma chamber 108 andthe RF transmission line 139 coupled to the output of the IMN 112 withan impedance of the bias RF generator system 114 and the RF cable system137 coupled to the one or more inputs of the IMN 112. In one embodiment,one or more of the electrical circuit components of the IMN 112 aretuned to facilitate a match between an impedance of the load coupled tothe output of the IMN 112 with that of the source coupled to the one ormore inputs of the IMN 112. The IMN 112 reduces a probability of RFpower being reflected in a direction towards the source, such as, fromthe load towards the source.

The RF generator RFGx includes a digital signal processor DSPx, a powerparameter controller PWRS1x, another power parameter controller PWRS2x,an auto frequency tuner (AFT) AFTS1x, another auto frequency tunerAFTS2x, an RF power supply Psx, and a driver system 118. Examples of anRF power supply, as used herein, include an RF oscillator. Toillustrate, an RF power supply is an electronic circuit that produces anoscillating signal, such as a sine wave, at a radio frequency. Asanother illustration, an RF power supply is a crystal oscillator havinga quartz crystal that is distorted at a pre-determined frequency when avoltage is applied to an electrode near or on the quartz crystal. Asused herein, a processor is an application specific integrated circuit(ASIC), or a programmable logic device (PLD), or a central processingunit (CPU), or a microprocessor, or a microcontroller. As used herein, acontroller is application specific integrated circuit (ASIC), or aprogrammable logic device (PLD), or a central processing unit (CPU), ora microprocessor, or a microcontroller, or a processor. Examples of adriver system, as used herein, include one or more transistors.

The plasma chamber 108 includes a dielectric window 120, which forms apart of an upper wall of the plasma chamber 108. The dielectric window120 separates an upper electrode 106 from an inside volume of the plasmachamber 108. The dielectric window 120 controls, such as reduces, aneffect of an electric field that is induced by the upper electrode 106within the inside of the volume of the plasma chamber 108. An example ofthe upper electrode 106 includes a transformer coupled plasma (TCP)coil, which includes one or more coil turns. For example, each coil turnlies in the same horizontal plane. As another example, each coil turnlies in a different horizontal plane. The upper electrode 106 isinductively coupled to the inside volume of the plasma chamber 108 viathe dielectric window 120. Examples of materials used to fabricate thedielectric window 120 include quartz, or ceramic, etc. In someembodiments, the plasma chamber 108 also includes other components (notshown), e.g., a lower dielectric ring surrounding the chuck 110, a lowerelectrode extension surrounding the lower dielectric ring, a lowerplasma exclusion zone (PEZ) ring, etc. The upper electrode 106 islocated opposite to and facing the chuck 110, which includes a lowerelectrode. For example, the chuck 110 includes a ceramic layer that isattached to top of the lower electrode and a facility plate that isattached to bottom of the lower electrode. The lower electrode is madeof a metal, e.g., anodized aluminum, alloy of aluminum, etc. Also, theupper electrode 106 is made of a metal.

A substrate 122, e.g., a semiconductor wafer, is supported on an uppersurface of the chuck 110. Integrated circuits, e.g., an ASIC, a PLD,etc., are developed on the substrate 122 and the integrated circuits areused in a variety of devices, e.g., cell phones, tablets, smart phones,computers, laptops, networking equipment, etc.

One or more inlet ports, such as formed within a side wall of the plasmachamber 108, are coupled to a central gas feed (not shown). The centralgas feed receives one or more process gases from a gas supply (notshown). Examples of the one or more process gases include anoxygen-containing gas, such as O₂. Other examples of the one or moreprocess gases include a fluorine-containing gas, e.g.,tetrafluoromethane (CF₄), sulfur hexafluoride (SF₆), hexafluoroethane(C₂F₆), etc.

The DSPx is coupled to the power parameter controllers PWRS1x andPWRS2x, and to the auto-frequency tuners AFTS1x and AFTS2x. Moreover,the power parameter controllers PWRS1x and PWRS2x and the auto-frequencytuners AFTS1x and AFTS2x are coupled to the driver system 118. Thedriver system 118 is coupled to the RF power supply Psx. The RF powersupply Psx is coupled via an output of the RF generator RFGx to an RFcable 124, which is coupled to an input of the IMN 104.

An output of the IMN 104 is coupled via an RF transmission cable 126 toan end E1 of the upper electrode 106. The upper electrode 106 is coupledto a ground potential at its opposite end, such as an end E2. An exampleRF transmission cable 126 is an RF cable.

The RF generator RFGy includes a DSPy, a power parameter controllerPWRS1y, another power parameter controller PWRS2y, an auto frequencytuner AFTS1y, and another auto frequency tuner AFTS2y. The RF generatorRFGy further includes an RF power supply Psy and a driver system 128.The DSPy is coupled to the power parameter controllers PWRS1y andPWRS2y, and to the auto-frequency tuners AFTS1y and AFTS2y. Moreover,the power parameter controllers PWRS1y and PWRS2y and the auto-frequencytuners AFTS1y and AFTS2y are coupled to the driver system 128. Thedriver system 128 is coupled to the RF power supply Psy. The RF powersupply Psy is coupled via an output of the RF generator RFGy to an RFcable 130, which is coupled to another input of the IMN 104. The otherinput of the IMN 104 to which the RF cable 130 is coupled is differentfrom the input to which the RF cable 124 is coupled.

The IMN 104 includes electric circuit components, e.g., inductors,capacitors, resistors, or a combination of two or more thereof, etc. tomatch an impedance of a load coupled to the output of the IMN 104 withan impedance of a source coupled to the inputs of the IMN 104. Forexample, the IMN 104 matches an impedance of the plasma chamber 108 andthe RF transmission cable 126 coupled to the output of the IMN 104 withan impedance of the RF generator RFGx, the RF cable 124, the RFgenerator RFGy, and the RF cable 130. In one embodiment, one or more ofthe electrical circuit components of the IMN 104 are tuned to facilitatea match between an impedance of the load coupled to the output of theIMN 104 with that of the source coupled to the inputs of the IMN 104.The IMN 104 reduces a probability of RF power being reflected adirection towards the source, e.g., from the load towards the source.

The host computer 116 includes a processor 132 and a memory device 134.The processor 132 is coupled to the memory device 134. Examples of amemory device include a random access memory (RAM) and a read-onlymemory (ROM). To illustrate, a memory device is a flash memory, a harddisk, or a storage device, etc. A memory device is an example of acomputer-readable medium. The processor 132 is coupled to the DSPx via acable 136 and is coupled to the DSPy via a cable 138. Examples of thecable 136 or the cable 138 include a cable that is used to transfer datain a serial manner, a cable that is used to transfer data in a parallelmanner, and a cable that is used to transfer data by applying auniversal serial bus (USB) protocol.

A control circuit of the processor 132 is used to generate a pulsedsignal 102, e.g., a transistor-transistor logic (TTL) signal, a digitalpulsing signal, a clock signal, a signal with a duty cycle, etc.Examples of the control circuit of the processor 132 used to generatethe pulsed signal 102 includes a TTL circuit.

The pulsed signal 102 includes multiple states S1 and S2. For example,the state S1 of the pulsed signal 102 has a logic level of one during aportion of a cycle of the pulsed signal 102 and a logic level of zeroduring another portion of the cycle. In various embodiments, the statesS1 and S2 execute once during the cycle of the pulsed signal 102 andrepeat with multiple cycles of the pulsed signal 102. For example, thecycle of the pulsed signal 102 includes the states S1 and S2 and anothercycle of the pulsed signal 102 includes the states S1 and S2. Toillustrate, during a portion of a period of the cycle of the pulsedsignal 102, the state S1 is executed and during the remaining period ofthe cycle, the state S2 is executed. As another example, the duty cycleof the state S1 is the same as the duty cycle of the state S2. Toillustrate, each state S1 and S2 of the pulsed signal 102 has a dutycycle of 50%. As yet another example, the duty cycle of the state S1 isdifferent from the duty cycle of the state S2. To illustrate, the stateS1 of the pulsed signal 102 has the duty cycle of a% and the state S2 ofthe pulsed signal 102 has the duty cycle of (100-a)%, where a is aninteger greater than zero. An example of a% ranges between 10% and 50%.Another example of a% ranges between 20% and 40%. Yet another example ofa% is 25%.

In various embodiments, instead of the control circuit of the processor132, a clock source, e.g., a crystal oscillator, etc., is used togenerate an analog clock signal, which is converted by ananalog-to-digital converter into a digital signal similar to the pulsedsignal 102. For example, the crystal oscillator is made to oscillate inan electric field by applying a voltage to an electrode near the crystaloscillator. In various embodiments, instead of the processor 132, adigital clock source generates the pulsed signal 102.

The processor 132 accesses a recipe from the memory device 134. Examplesof the recipe include a power parameter set point to be applied to theRF generator RFGx for the state S1, a power parameter set point to beapplied to the RF generator RFGx for the state S2, a frequency set pointto be applied to the RF generator RFGx for the state S1, a frequency setpoint to be applied to the RF generator RFGx for the state S2, a powerparameter set point to be applied to the RF generator RFGy for the stateS1, a power parameter set point to be applied to the RF generator RFGyfor the state S2, a frequency set point to be applied to the RFgenerator RFGy for the state S1, a frequency set point to be applied tothe RF generator RFGy for the state S2, a chemistry of the one or moreprocess gases, or a combination thereof. Examples of a power parameterset point, as used herein, include a voltage set point and a power setpoint.

The processor 132 sends an instruction with the pulsed signal 102 to theDSPx via the cable 136. The instruction sent to the DSPx via the cable136 has information regarding the pulsed signal 102, the power parameterset point to be applied to the RF generator RFGx for the state S1, thepower parameter set point to be applied to the RF generator RFGx for thestate S2, the frequency set point to be applied to the RF generator RFGxfor the state S1, and the frequency set point to be applied to the RFgenerator RFGx for the state S2. The information regarding the pulsedsignal 102 indicates to the DSPx that the RF signal to be generated bythe RF generator RFGx is to transition from the state S1 to the state S2at a transition time tst1 of the pulsed signal 102 and that the RFsignal is to transition from the state S2 to the state S1 at atransition time tst2 of the pulsed signal 102. The DSPx determines fromthe instruction that the power parameter set point for the state S1 isto be applied during the state S1 of the pulsed signal 102, the powerparameter set point for the state S2 is to be applied during the stateS2 of the pulsed signal 102, the frequency set point for the state S1 isto be applied during the state S1 of the pulsed signal 102, and thefrequency set point for the state S2 is to be applied during the stateS2 of the pulsed signal 102. Moreover, the DSPx determines from theinstruction and the pulsed signal 102, that the RF signal to begenerated by the RF generator RFGx is to transition from the state S1 tothe state S2 at the transition time tst1 of the pulsed signal 102 andthat the RF signal is to transition from the state S2 to the state S1 atthe transition time tst2 of the pulsed signal 102. The transition timestst1 and tst2 repeat for each cycle of the pulsed signal 102.

At the transition time tst2 of the cycle of the pulsed signal 102, theDSPx sends the power parameter set point for the state S1 to the powerparameter controller PWRS1x. Similarly, at the transition time tst1 ofthe cycle of the pulsed signal 102, the DSPx sends the power parameterset point for the state S2 to the power parameter controller PWRS2x.Moreover, at the transition time tst2 of the cycle of the pulsed signal102, the DSPx sends the frequency set point for the state S1 to theauto-frequency tuner AFTS1x. Also, at the transition time tst1 of thecycle of the pulsed signal 102, the DSPx sends the frequency set pointfor the state S2 to the auto-frequency tuner AFTS2x.

Upon receiving the power parameter set point for the state S1, the powerparameter controller PWRS1x determines an amount of currentcorresponding to, e.g., having a one-to-one relationship with, mappedto, linked to, etc., the power parameter set point for the state S1.Based on the amount of current that is to be generated by the driversystem 118 during the state S1, the power parameter controller PWRS1xgenerates a command signal and sends the command signal to the driversystem 118. For the state S1, in response to receiving the commandsignal, the driver system 118 generates and sends a current signalhaving the amount of current to the RF power supply Psx. The RF powersupply Psx, upon receiving the current signal generates the RF signalhaving the power parameter set point for the state S1 and supplies theRF signal via the output of the RF generator RFGx and the RF cable 124to the input of the IMN 104. The power parameter set point for the stateS1 is maintained during the state S1 by the RF power supply Psx of theRF generator RFGx.

Similarly, upon receiving the power parameter set point for the stateS2, the power parameter controller PWRS2x determines an amount ofcurrent corresponding to the power parameter set point for the state S2.Based on the amount of current that is to be generated by the driversystem 118 during the state S2, the power parameter controller PWRS2xgenerates a command signal and sends the command signal to the driversystem 118. For the state S2, in response to receiving the commandsignal, the driver system 118 generates and sends a current signalhaving the amount of current to the RF power supply Psx. The RF powersupply Psx, upon receiving the current signal generates the RF signalhaving the power parameter set point for the state S2 and supplies theRF signal via the output of the RF generator RFGx and the RF cable 124to the input of the IMN 104. The power parameter set point for the stateS2 is maintained during the state S2 by the RF power supply Psx of theRF generator RFGx.

Moreover, upon receiving the frequency set point for the state S1, theauto-frequency tuner AFTS1x determines an amount of currentcorresponding to the frequency set point for the state S1. Based on theamount of current that is to be generated by the driver system 118during the state S1, the auto-frequency tuner AFTS1x generates a commandsignal and sends the command signal to the driver system 118. For thestate S1, in response to receiving the command signal, the driver system118 generates and sends a current signal having the amount of current tothe RF power supply Psx. The RF power supply Psx, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S1 and supplies the RF signal via the output of the RFgenerator RFGx and the RF cable 124 to the input of the IMN 104. Thefrequency set point for the state S1 is maintained during the state S1by the RF power supply Psx. The RF signal having the power parameter setpoint for the state S1 and the frequency set point for the state S1 isthe RF signal generated by the RF generator RFGx during the state S1.

Similarly, upon receiving the frequency set point for the state S2, theauto-frequency tuner AFTS2x determines an amount of currentcorresponding to the frequency set point for the state S2. Based on theamount of current that is to be generated by the driver system 118during the state S2, the auto-frequency tuner AFTS2x generates a commandsignal and sends the command signal to the driver system 118. For thestate S2, in response to receiving the command signal, the driver system118 generates and sends a current signal having the amount of current tothe RF power supply Psx. The RF power supply Psx, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S2 and supplies the RF signal via the output of the RFgenerator RFGx and the RF cable 124 to the input of the IMN 104. Thefrequency set point for the state S2 is maintained during the state S2by the RF power supply Psx. The RF signal having the power parameter setpoint for the state S2 and the frequency set point for the state S2 isthe RF signal generated by the RF generator RFGx during the state S2.

The processor 132 sends an instruction with the pulsed signal 102 to theDSPy via the cable 138. The instruction sent to the DSPy via the cable138 has information regarding the pulsed signal 102, the power parameterset point to be applied to the RF generator RFGy for the state S1, thepower parameter set point to be applied to the RF generator RFGy for thestate S2, the frequency set point to be applied to the RF generator RFGyfor the state S1, and the frequency set point to be applied to the RFgenerator RFGy for the state S2. The information regarding the pulsedsignal 102 indicates to the DSPy that the RF signal to be generated bythe RF generator RFGy is to transition from the state S1 to the state S2at the transition time tst1 of the cycle of the pulsed signal 102 andthat the RF signal is to transition from the state S2 to the state S1 atthe transition time tst2 of the cycle of the pulsed signal 102. The DSPyparses the instruction and determines from the instruction that thepower parameter set point for the state S1 is to be applied during thestate S1 of the pulsed signal 102, the power parameter set point for thestate S2 is to be applied during the state S2 of the pulsed signal 102,the frequency set point for the state S1 is to be applied during thestate S1 of the pulsed signal 102, and the frequency set point for thestate S2 is to be applied during the state S2 of the pulsed signal 102.Moreover, the DSPy determines from the instruction that the RF signal tobe generated by the RF generator RFGy is to transition from the state S1to the state S2 at the transition time tst1 of the cycle of the pulsedsignal 102 and that the RF signal is to transition from the state S2 tothe state S1 at the transition time tst2 of the cycle of the pulsedsignal 102.

At the transition time tst2 of the cycle of the pulsed signal 102, theDSPy sends the power parameter set point for the state S1 to the powerparameter controller PWRS1y. Similarly, at the transition time tst1 ofthe cycle of the pulsed signal 102, the DSPy sends the power parameterset point for the state S2 to the power parameter controller PWRS2y.Moreover, at the transition time tst2 of the cycle of the pulsed signal102, the DSPy sends the frequency set point for the state S1 to theauto-frequency tuner AFTS1y. Also, at the transition time tst1 of thecycle of the pulsed signal 102, the DSPy sends the frequency set pointfor the state S2 to the auto-frequency tuner AFTS2y.

Upon receiving the power parameter set point for the state S1, the powerparameter controller PWRS1y determines an amount of currentcorresponding to the power parameter set point for the state S1. Basedon the amount of current that is to be generated by the driver system128 during the state S1, the power parameter controller PWRS1y generatesa command signal and sends the command signal to the driver system 128.For the state S1, in response to receiving the command signal, thedriver system 128 generates and sends a current signal having the amountof current to the RF power supply Psy. The RF power supply Psy, uponreceiving the current signal generates the RF signal having the powerparameter set point for the state S1 and supplies the RF signal via theoutput of the RF generator RFGy and the RF cable 130 to the other inputof the IMN 104. The power parameter set point for the state S1 ismaintained during the state S1 by the RF power supply Psy.

Similarly, upon receiving the power parameter set point for the stateS2, the power parameter controller PWRS2y determines an amount ofcurrent corresponding to the power parameter set point for the state S2.Based on the amount of current that is to be generated by the driversystem 128 during the state S2, the power parameter controller PWRS2ygenerates a command signal and sends the command signal to the driversystem 128. For the state S2, in response to receiving the commandsignal, the driver system 128 generates and sends a current signalhaving the amount of current to the RF power supply Psy. The RF powersupply Psy, upon receiving the current signal generates the RF signalhaving the power parameter set point for the state S2 and supplies theRF signal via the output of the RF generator RFGy and the RF cable 130to the other input of the IMN 104. The power parameter set point for thestate S2 is maintained during the state S2 by the RF power supply Psy.

Moreover, upon receiving the frequency set point for the state S1, theauto-frequency tuner AFTS1y determines an amount of currentcorresponding to the frequency set point for the state S1. Based on theamount of current that is to be generated by the driver system 128during the state S1, the auto-frequency tuner AFTS1y generates a commandsignal and sends the command signal to the driver system 128. For thestate S1, in response to receiving the command signal, the driver system128 generates and sends a current signal having the amount of current tothe RF power supply Psy. The RF power supply Psy, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S1 and supplies the RF signal via the output of the RFgenerator RFGy and the RF cable 130 to the other input of the IMN 104.The frequency set point for the state S1 is maintained during the stateS1 by the RF power supply Psy. The RF signal having the power parameterset point for the state S1 and the frequency set point for the state S1is the RF signal generated by the RF generator RFGy during the state S1.

Similarly, upon receiving the frequency set point for the state S2, theauto-frequency tuner AFTS2y determines an amount of currentcorresponding to the frequency set point for the state S2. Based on theamount of current that is to be generated by the driver system 128during the state S2, the auto-frequency tuner AFTS2y generates a commandsignal and sends the command signal to the driver system 128. For thestate S2, in response to receiving the command signal, the driver system128 generates and sends a current signal having the amount of current tothe RF power supply Psy. The RF power supply Psy, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S2 and supplies the RF signal via the output of the RFgenerator RFGy and the RF cable 130 to the other input of the IMN 104.The frequency set point for the state S2 is maintained during the stateS2 by the RF power supply Psy. The RF signal having the power parameterset point for the state S2 and the frequency set point for the state S2is the RF signal generated by the RF generator RFGy during the state S2.

The input of the IMN 104 receives the RF signal generated by the RFpower supply Psx via the RF cable 124 from the output of the RFgenerator RFGx, receives, at the other input, the RF signal generated bythe RF power supply Psy via the RF cable 130 from the output of the RFgenerator RFGy, and matches an impedance of the load coupled to theoutput of the IMN 104 with an impedance of the source coupled to theinputs of the IMN 104 to generate a modified RF signal at the output ofthe IMN 104. The modified RF signal is sent via the RF transmissioncable 126 to the upper electrode 106, such as to the end E1 of the TCPcoil.

Moreover, the RF generator system 114 generates one or more RF signals.For example, an RF generator of the RF generator system 114 generates anRF signal. As another example, an RF generator of the RF generatorsystem 114 generates an RF signal and another RF generator of the RFgenerator system 114 generates another RF signal. It should be notedthat an amount of bias voltage or bias power of the one or more RFsignals that are supplied by the RF generator system 114 is within apre-determined range during multiple states, such as the states S1 andS2, or the states S1, S2, and a state S3. To illustrate, the processor132 sends a level of the bias voltage or a level of bias power to the RFgenerator system 114 via a cable 117 that couples the RF generatorsystem 114 to the processor 132. The RF generator system 114 generatesthe one or more RF signals having the level of bias voltage or the levelof bias power during the multiple states. The one or more RF signals aregenerated by the RF generator system 114 in a manner similar to thatdescribed herein for generating the RF signal generated by the RFgenerator RFGx or RFGy. The bias voltage or the bias power of the one ormore RF signals is constant, such as the same as, or within thepre-determined range from the level of bias voltage or the level of biaspower that is received from the processor 132. The bias RF generatorsystem 114 operates in a continuous wave mode during the states S1 andS2 or the states S1 through S3.

The one or more RF signals are received by the IMN 112 via the RF cablesystem 137 to match an impedance of the load coupled to the output ofthe IMN 112 with that of the source coupled to the one or more inputs ofthe IMN 112 to generate an output RF signal. The output RF signal issent via the RF transmission line 139 to the chuck 110.

When the one or more process gases are supplied between the upperelectrode 106 and the chuck 110, the modified RF signal is supplied tothe upper electrode 106, and the output RF signal is supplied to thechuck 110, the one or more process gases are ignited to generate ormaintain plasma within the plasma chamber 108. The plasma has a plasmasheath 123 and is used to process, e.g., etch, deposit materials on,clean, sputter, etc., the substrate 122. The plasma sheath 123 is aboundary of the plasma formed within the plasma chamber 108. Forexample, the plasma sheath 123 includes a top boundary 125A of theplasma formed within the plasma chamber 108 and a bottom boundary 125Bof the plasma formed within the plasma chamber 108. The top boundary125A is closer to the upper electrode 106 than to the chuck 110 and thebottom boundary 125B is closer to the chuck 110 than to the upperelectrode 106.

In some embodiments, the terms tuner and controller are usedinterchangeably herein.

In various embodiments, the power parameter controllers PWRS1x andPWRS2x, and the auto-frequency tuners AFTS1x and AFTS2x are modules,e.g., portions, etc., of a computer program that is executed by theDSPx. Similarly, in some embodiments, the power parameter controllersPWRS1y and PWRS2y, and the auto-frequency tuners AFTS1y and AFTS2y aremodules, e.g., portions, etc., of a computer program that is executed bythe DSPy.

In several embodiments, the power parameter controllers PWRS1x andPWRS2x, and the auto-frequency tuners AFTS1x and AFTS2x are separateintegrated circuits that are coupled to an integrated circuit of theDSPx. For example, the power parameter controller PWRS1x is a firstintegrated circuit of the RF generator RFGx, the power parametercontroller PWRS2x is a second integrated circuit of the RF generatorRFGx, the auto-frequency tuner AFTS1x is a third integrated circuit ofthe RF generator RFGx, the auto-frequency tuner AFTS2x is a fourthintegrated circuit of the RF generator RFGx, and the DSPx is a fifthintegrated circuit of the RF generator RFGx. Each of the first throughfourth integrated circuit of the RF generator RFGx is coupled to thefifth integrated circuit of the RF generator RFGx.

Similarly, in various embodiments, the power parameter controllersPWRS1y and PWRS2y, and the auto-frequency tuners AFTS1y and AFTS2y areseparate integrated circuits that are coupled to an integrated circuitof the DSPy. For example, the power parameter controller PWRS1y is afirst integrated circuit of the RF generator RFGy, the power parametercontroller PWRS2y is a second integrated circuit of the RF generatorRFGy, the auto-frequency tuner AFTS1y is a third integrated circuit ofthe RF generator RFGy, the auto-frequency tuner AFTS2y is a fourthintegrated circuit of the RF generator RFGy, and the DSPy is a seventhintegrated circuit of the RF generator RFGy. Each of the first throughfourth integrated circuit of the RF generator RFGy is coupled to thefifth integrated circuit of the RF generator RFGy.

In various embodiments, an example of the state S1 of an RF signal,described herein, includes the power parameter set point for the stateS1 and the frequency set point for the state S1. The power parameter setpoint for the state S1 is an operational power parameter set point,which is a power parameter level, such as an envelope or a zero-to-peakmagnitude, of power amounts or voltage amounts of the RF signal duringthe state S1. The frequency set point for the state S1 is an operationalfrequency set point, which is a frequency level, such as an envelope ora zero-to-peak magnitude, of frequency values of the RF signal duringthe state S1. Similarly, an example of the state S2 of the RF signal,described herein, includes the power parameter set point for the stateS2 and the frequency set point for the state S2. The power parameter setpoint for the state S2 is an operational power parameter set point,which is a power parameter level, such as an envelope or a zero-to-peakmagnitude, of power amounts or voltage amounts of the RF signal duringthe state S2. The frequency set point for the state S2 is an operationalfrequency set point, which is a frequency level, such as an envelope ora zero-to-peak magnitude, of frequency values of the RF signal duringthe state S2. It should be noted that in an embodiment, a powerparameter level of zero is an example of a power parameter set point,described herein. Similarly, in one embodiment, a frequency level ofzero is an example of a frequency set point, described herein.

In various embodiments, three RF generators are coupled to the IMN 104.For example, an additional RF generator is coupled to the IMN 104 viaanother RF cable (not shown) to yet another input of the IMN 104. Theadditional RF generator is in addition to the RF generator RFGx and theRF generator RFGy. The yet another input is not the same as the input ofthe IMN 104 to which the RF cable 124 is coupled or the other input ofthe IMN 104 to which to the RF cable 130 is coupled. The additional RFgenerator has the same structure and function as that of the RFgenerator RFGy except that the additional RF generator has a differentoperating frequency, e.g., 2 MHz, 27 MHz, 60 MHz, etc., than that of theRF generator RFGy. For example, the RF generator RFGy has an operatingfrequency of 13.56 MHz and the additional RF generator has an operatingfrequency of 2 MHz, or 27 MHz, or 60 MHz. The IMN 104 combines the RFsignals received from the RF generator RFGx, the RF generator RFGy, andthe additional RF generator, and matches an impedance of the loadcoupled to the output of the IMN 104 with that of a source, e.g., the RFgenerator RFGx, the RF generator RFGy, the additional RF generator, theRF cable 124, the RF cable 130, and the other RF cable, etc., togenerate the modified RF signal at the output of the IMN 104.

In one embodiment, terms impedance matching circuit and impedancematching network are used herein interchangeably.

In some embodiments, the chuck 110 is coupled to the ground potentialinstead of being coupled to the IMN 112 and the bias RF generator system114.

In various embodiments, instead of the TCP coil being used as the upperelectrode 106, a CCP plate is used at the upper electrode 106. Forexample, the CCP plate is a circular plate having a circular volume andlies in a horizontal plane inside the plasma chamber 108. The CCP plateis made of a metal, such as aluminum or an alloy of aluminum. In theseembodiments, the plasma chamber 108 lacks the dielectric window 120 andhas an upper wall instead. The plasma chamber 108 also includes othercomponents, such as an upper dielectric ring surrounding the CCP plate,an upper electrode extension surrounding the upper dielectric ring, anupper PEZ ring, etc. The CCP plate is located opposite to and facing thechuck 110.

In some embodiments, instead of the pulsed signal 102 being sent fromthe processor 132 to the RF generators RFGx and RFGy, the pulsed signal102 is sent from a master RF generator to a slave RF generator, such asthe RF generator RFGy. An example of the master RF generator includesthe RF generator RFGx. To illustrate, the digital signal processor DSPxof the RF generator RFGx receives the pulsed signal 102 from theprocessor 132 and sends the pulsed signal 102 via a cable, such as aparallel transfer cable, a serial transfer cable, or a USB cable, to thedigital signal processor DSPy of the RF generator RFGy. FIG. 1B is adiagram of embodiments of graphs 140, 142, and 144. The graph 140 plotsa logic level of the pulsed signal 102 versus the time t. Examples ofthe logic level include a level of zero and a level of one. The level ofzero is an example of a low logic level and the level of one is anexample of a high logic level. Moreover, the graph 142 plots a powerparameter level, such as a voltage level or a power level, of the RFsignal, such as an RF signal 146A, that is generated and supplied by theRF generator RFGx versus the time t. The graph 142 further plots thepower parameter level of the RF signal, such as an RF signal 146B, thatis generated and supplied by the RF generator RFGy versus the time t.Also, the graph 144 plots the power parameter level of the RF signal146A versus the time t. The graph 144 further plots the power parameterlevel of the RF signal, such as an RF signal 146C, generated andsupplied by the RF generator RFGy versus the time t.

With reference to graphs 140 and 142, during each cycle of the pulsedsignal 102, the pulsed signal 102 transitions from the state S1 to thestate S2 at the transition time tst1 and transitions from the state S2to the state S1 at the transition time tst1. Moreover, during the stateS1, the RF signal 146A has a power parameter level of Px1 and the RFsignal 146B has a power parameter level of zero. Also, during the stateS1, the RF signal 146A has a frequency level of fx1 and the RF signal146B has a frequency level of zero.

Furthermore, at the transition time tst1, each RF signal 146A and 146Btransitions from the state S1 to the state S2. During the state S2, theRF signal 146A has a power parameter level of zero and the RF signal146B has a power parameter level of Py2. Also, during the state S2, theRF signal 146A has a frequency level of zero and the RF signal 146B hasa frequency level of fy2. When any RF generator, described herein,operates at a frequency level of zero and at a power parameter level ofzero, the RF generator is turned off, e.g., is nonoperational, isswitched off, etc. The power parameter level Py2 is the same as thepower parameter level Px1. Moreover, the frequency level fy2 is greaterthan the frequency level fx1. At the transition time tst2, each RFsignal 146A and 146B transitions from the state S2 back to the state S1.

It should further be noted that a duty cycle of the state S1 of thepulsed signal 102 or the RF signal 146A or the RF signal 146B is thesame as a duty cycle of the state S2 of the pulsed signal 102 or the RFsignal 146A or the RF signal 146B. For example, the duty cycle of thestate S1 is 50% and the duty cycle of the state S2 is 50%. The state S1of the RF signal 146A or the RF signal 146B occupies 50% of the cycle ofthe pulsed signal 102 and the state S2 of the RF signal 146A or the RFsignal 146B occupies the remaining 50% of the cycle of the pulsed signal102.

In various embodiments, a duty cycle of the state S1 of a signal, suchas the pulsed signal 102 or the RF signal 146A or the RF signal 146B, isdifferent from a duty cycle of the state S2 of the signal. For example,the duty cycle of the state S1 is 25% and the duty cycle of the state S2is 75%. The state S1 of the RF signal 146A or the RF signal 146Boccupies 25% of the cycle of the pulsed signal 102 and the state S2 ofthe RF signal 146A or the RF signal 146B occupies the remaining 75% ofthe cycle of the pulsed signal 102. As another example, the duty cycleof the state S1 is a% and the duty cycle of the state S2 is (100-a)%.The state S1 of the RF signal 146A or the RF signal 146B occupies a% ofthe cycle of the pulsed signal 102 and the state S2 of the RF signal146A or the RF signal 146B occupies the remaining (100-a)% of the cycleof the pulsed signal 102. To illustrate, during a calibration operation,for a frequency level for the state S1, a frequency level for the stateS2, a power parameter level for the state S1, and a power parameterlevel for the state S2, a type of the one or more process gases, and atype of a material of the substrate 122, a percentage of the cycle ofthe pulsed signal 102 for which the RF signal is generated by the RFgenerator RFGx is determined based on an etch rate to be achieved. Theetch rate is measured by an etch rate measurement device (ERMD) duringthe calibration operation. Examples of the type of the material of thesubstrate 120 to include an oxide layer or a metal layer of thesubstrate 122. Moreover, the percentage of the cycle of the pulsedsignal 102, for which the RF signal is generated by the RF generatorRFGx, is associated with a threshold amount of charge to be stored onthe plasma sheath 123 during the state S1. The association between thethreshold amount of charge, the etch rate, and the percentage of thecycle of the pulsed signal 102 for which the RF signal is generated bythe RF generator RFGx is stored in the memory device 134. Duringprocessing of the substrate 122, the percentage of the cycle of thepulsed signal 102, for which the RF signal is generated by the RFgenerator RFGx, is used as a part of a recipe or as a duty cycle of thepulsed signal 102.

The ERMD is coupled to the processor 132 via a cable and has a line ofsight via a window of the plasma chamber 108. The line of sight isdirected into a space in which plasma is generated within the plasmachamber 108. For example, the ERMD includes a spectrophotometer thatmonitors plasma within the plasma chamber 108 to measure intensity ofradiation emitted by the plasma via the window. In some embodiments, thewindow is made of a transparent material that allows light emitted bythe plasma to pass through, e.g., glass. In various embodiments, thewindow is a translucent window. The intensity is directly proportionalto an etch rate of a layer of a dummy wafer that is etched by theplasma. As another example, for a known recipe, from intensities ofradiation emitted by the plasma during the calibration operation, theERMD measures a thickness of the dummy wafer at a time tm1 and measuresa thickness of the dummy wafer at a time tm2, after time tm1 and afteretching the dummy wafer. The ERMD determines an etch rate of the dummywafer as a ratio of a difference between the thickness at the time tm2and the thickness at the time tm1 over a difference between the timestm2 and tm1. In various embodiments, the dummy wafer has the samematerial as that of the substrate 122.

In some embodiments, the power parameter level Py2 of the RF signal 146Bis different from, such as is lower than or greater than, the powerparameter level Px1 of the RF signal 146A.

The graph 144 is similar to the graph 142 except that the RF signals146B and 146C have different power parameter levels. For example, the RFsignal 146B has the power parameter level of Py2 during the state S2 andthe power parameter level Py2 of the RF signal 146B is greater than apower parameter level Py2 of the RF signal 146C.

With reference to graphs 140 and 144, the state S1 of the RF signal 146Cis the same as the state S1 of the RF signal 146B. For example, duringthe state S1, the RF signal 146C has a power parameter level of zero.Also, during the state S1, the RF signal 146C has a frequency level ofzero.

Furthermore, at the transition time tst1, the RF signal 146C transitionsfrom the state S1 to the state S2. During the state S2, the RF signal146C has the power parameter level of Py2. Also, during the state S2,the RF signal 146C has the frequency level of fy2. The power parameterlevel Py2 of the RF signal 146C is lower than the power parameter levelPx1 of the RF signal 146A and the frequency level fy2 of the RF signal146C is the same as the frequency level of the RF signal 146B. At thetransition time tst2, the RF signal 146C transitions from the state S2back to the state S1.

It should be noted that a duty cycle of the state S1 of the RF signal146C is the same as a duty cycle of the state S2 of the RF signal 146C.For example, the duty cycle of the state S1 of the RF signal 146C is 50%and the duty cycle of the state S2 of the RF signal 146C is 50%. Thestate S1 of the RF signal 146C occupies 50% of the cycle of the pulsedsignal 102 and the state S2 of the RF signal 146C occupies the remaining50% of the cycle of the pulsed signal 102.

In various embodiments, a duty cycle of the state S1 of the RF signal146C is different from a duty cycle of the state S2 of the RF signal146C. For example, the duty cycle of the state S1 of the RF signal 146Cis 25% and the duty cycle of the state S2 of the RF signal 146C is 75%.The state S1 of the RF signal 146C occupies 25% of the cycle of thepulsed signal 102 and the state S2 of the RF signal 146C occupies theremaining 75% of the cycle of the pulsed signal 102. As another example,the duty cycle of the state S1 of the RF signal 146C is a% and the dutycycle of the state S2 of the RF signal 146C is (100-a)%. The state S1 ofthe RF signal 146C occupies a% of the cycle of the pulsed signal 102 andthe state S2 of the RF signal 146C occupies the remaining (100-a)% ofthe cycle of the pulsed signal 102.

In some embodiments, the power parameter level Py2 of the RF signal 146Cis greater than the power parameter level Px1 of the RF signal 146A.

It should be noted that the power parameter levels Px1 and Py2 arenon-zero as illustrated in the graph 142. Moreover, the frequency levelsfx1 and fy2 are non-zero as illustrated in the graph 142. Also, thepower parameter levels Px1 and Py2 are non-zero as illustrated in thegraph 144. Moreover, the frequency levels fx1 and fy2 are non-zero asillustrated in the graph 144.

It should further be noted that the RF generator RFGx is controlled tooperate at the frequency level fx1 during the state S1. Within theplasma chamber 108, the power parameter of the RF signal generated bythe RF generator RFGx during the state S1 is added to the powerparameter of the RF signal generated by the RF generator RFGy during thestate S2. The plasma sheath 123 within the plasma chamber 108 acts as acapacitor. The capacitor charges during the state S1 from the powerparameter level Px1 associated with the frequency level fx1 anddischarges during the state S2. The power parameter level Px1 chargesthe plasma sheath 123 to increase an amount of charge of the plasmasheath 123 during the state S1. Moreover, the charging of the plasmasheath 123 during the state S1 increases a thickness of the plasmasheath 123 during the state S1. For example, as a number of plasma ionsgenerated during the state S1 accumulate on the plasma sheath 123 duringthe state S1, there is an increase in a thickness of the plasma sheath123 during the state S1. The charging occurs to add a portion of thepower parameter level Px1 to the power parameter level Py2. The additionof the portion of the power parameter level Px1 to the power parameterlevel Py2 and the discharging of the capacitor during the state S2increases ion energy of ions of plasma within the plasma chamber 108during the state S2 and decreases an angular spread of the ion energyduring the state S2. For example, a vertical directionality of plasmawithin the plasma chamber 108 increases during the state S2 with theaddition of the portion of the power parameter level Px1 to the powerparameter level Py2 during the state S2. Ion energy of plasma formedwithin the plasma chamber 108 is increased as a result of the additionof the portion of the power parameter level Px1 to the power parameterlevel Py2. A summed power parameter level, which includes the portion ofthe power parameter level Px1 and the power parameter level Px2,enhances the ion energy during the state S2. At least a portion ofcharge of the plasma sheath 123 that stores during the state S1 theenhanced ion energy is discharged during the state S2 from the topboundary 125A to the bottom boundary 125B of the plasma sheath 123 todecrease an angular spread of plasma ions incident on a top surface ofthe substrate 122 to further increase an etch rate of etching thesubstrate 122.

It should also be noted that during a time the RF generator RFGxoperates at the frequency set point for the state S1, there is anincrease in reactance of the plasma sheath 123 of plasma formed withinthe plasma chamber 108 during the state S1. The reactance of the plasmasheath 123 is inversely proportional to frequency of an RF generatorthat is operated to generate or maintain the plasma sheath 123. Becauseof high reactance of the plasma sheath 123 during the state S1 comparedto the state S2, ion current through the plasma sheath 123 decreasesduring the state S1.

With the increase in the reactance of the plasma sheath 123, there is adecrease in the ion current of plasma ions at a surface of the substrate122 during the state S1. A resistance R associated with the plasmasheath 123 is inversely proportional to square of the ion current forthe same amount of power of plasma ions during the states S1 and S2. Todeliver the same amount, such as a constant amount of power during thestates S1 and S2, there is an increase in the resistance R associatedwith the plasma sheath 123 during the state S1 with the decrease in theion current. The increased resistance R during the state S1 increases atime constant RC associated with the plasma sheath 123 during the stateS1, prolonging an average time constant for the states S1 and S2 toenhance peak energy and reduce an angle, such as angular spread, in anion energy and angular distribution function (IEADF), where C is acapacitance of the plasma sheath 123 and R is the resistance at anoutput of the plasma sheath 123. To illustrate, the output of the plasmasheath 123 is a portion of the plasma sheath 123 to which the ioncurrent flows to. With the increase in the resistance R during the stateS1, an average amount of resistance associated with the plasma sheath123 during the states S1 and S2 increases. An average time constant forthe states S1 and S2 increases with the increase in the average amountof resistance. With the increase in the average time constant, an amountof time taken for discharge of the plasma sheath 123 increases duringany or both the states S1 and S2. The increase in the amount of time todischarge increases peak ion energy of plasma of plasma volume betweenthe plasma sheath 123 during the states S1 and S2 and decreases anangular spread of ions of the plasma during the states S1 and S2.

Moreover, during the state S1, the plasma sheath 123 charges based onthe power parameter level for the state S1. For example, during thestate S1, the plasma sheath 123 acts as the capacitor and stores anamount of charge that is received from the modified RF signal generatedbased on the RF signal supplied by the RF generator RFGx. During thestate S2, the charge generated within the plasma sheath 123 based on thepower parameter level for the state S1, such as the portion of the powerparameter level for the state S1, is added to a charge within the plasmasheath 123 based on the power parameter level for the state S2 togenerate a total charge that corresponds to the summed power parameterlevel. The summed power parameter level is a total of the portion of thepower parameter level for the state S1 and the power parameter level forthe state S2. The total charge resides within the plasma sheath 123. Thetotal charge discharges during the state S2 according to the timeconstant RC for discharging of the plasma sheath 123 that acts as thecapacitor. For example, it takes time for the plasma sheath 123 todischarge but when continuous wave mode RF generator is used sheath doesnot have to discharge during plasma operation. As a result of thedischarge, there is an increase in ion energy that is incident on asurface of the substrate 122 to increase a vertical directionality ofplasma ions of plasma formed within the plasma chamber 108, to decreasean angular spread of the plasma ions, and to increase a rate ofprocessing, such as an etch rate or a sputtering rate, the substrate122.

In some embodiments, the portion of the power parameter level for thestate S1 is referred to herein as additive power.

FIG. 1C is a diagram of embodiments of graphs 140, 152, and 154. Thegraph 152 plots a power parameter level, such as a voltage level or apower level, of the RF signal, such as an RF signal 156A, that isgenerated and supplied by the RF generator RFGx versus the time t.Moreover, the graph 152 plots the power parameter level of the RFsignal, such as an RF signal 156B, generated and supplied by the RFgenerator RFGy versus the time t. Also, the graph 154 plots the powerparameter level of the RF signal 156A versus the time t. The graph 154furthermore plots the power parameter level of the RF signal, such as anRF signal 156C, generated and supplied by the RF generator RFGy versusthe time t.

With reference to graphs 140 and 152, during the state S1, the RF signal156A has the power parameter level of Px1 and the RF signal 156B has apower parameter level of Py1, which is non-zero. Also, during the stateS1, the RF signal 156A has the frequency level of fx1 and the RF signal156B has a frequency level of fy1, which is non-zero.

Furthermore, at the transition time tst1, each RF signal 156A and 156Btransitions from the state S1 to the state S2. During the state S2, theRF signal 156A has a power parameter level of Px2 and the RF signal 156Bhas the power parameter level of Py2. Also, during the state S2, the RFsignal 156A has a frequency level of fx2 and the RF signal 156B has thefrequency level of fy2. The power parameter levels Px1, Px2, Py1, andPy2 are the same. Moreover, the frequency level fx2 is greater than thefrequency level fx1 and the frequency level fy1 is lower than thefrequency level fy2. At the transition time tst2, each RF signal 156Aand 156B transitions from the state S2 back to the state S1.

In some embodiments, the frequency level fx2 of the RF signal 156A islower than the frequency level fx1 of the RF signal 156A and thefrequency level fy1 of the RF signal 156B is greater than the frequencylevel fy2 of the RF signal 156B. In several embodiments, the frequencylevel fx2 of the RF signal 156A is greater than the frequency level fx1of the RF signal 156A and the frequency level fy1 of the RF signal 156Bis greater than the frequency level fy2 of the RF signal 156B. Invarious embodiments, the frequency level fx2 of the RF signal 156A islower than the frequency level fx1 of the RF signal 156A and thefrequency level fy1 of the RF signal 156B is lower than the frequencylevel fy2 of the RF signal 156B.

It should be noted that a duty cycle of the state S1 of the pulsedsignal 102 or the RF signal 156A or the RF signal 156B is the same as aduty cycle of the state S2 of the pulsed signal 102 or the RF signal156A or the RF signal 156B. For example, the duty cycle of the state S1is 50% and the duty cycle of the state S2 is 50%. The state S1 of the RFsignal 156A or the RF signal 156B occupies 50% of the cycle of thepulsed signal 102 and the state S2 of the RF signal 156A or the RFsignal 156B occupies the remaining 50% of the cycle of the pulsed signal102.

In various embodiments, a duty cycle of the state S1 of a signal, suchas the pulsed signal 102 or the RF signal 156A or the RF signal 156B, isdifferent from a duty cycle of the state S2 of the signal. For example,the duty cycle of the state S1 is 25% and the duty cycle of the state S2is 75%. The state S1 of the RF signal 156A or the RF signal 156Boccupies 25% of the cycle of the pulsed signal 102 and the state S2 ofthe RF signal 156A or the RF signal 156B occupies the remaining 75% ofthe cycle of the pulsed signal 102. As another example, the duty cycleof the state S1 is a% and the duty cycle of the state S2 is (100-a)%.The state S1 of the RF signal 156A or the RF signal 156B occupies a% ofthe cycle of the pulsed signal 102 and the state S2 of the RF signal156A or the RF signal 156B occupies the remaining (100-a)% of the cycleof the pulsed signal 102.

The graph 154 is similar to the graph 152 except that the RF signals156A and 156C have different power parameter levels. For example, the RFsignal 156A has the power parameter levels of Px1 and Px2 during thestates S1 and S2 and the RF signal 156C has the power parameter levelsof Py1 and Py2 during the states S1 and S2. The power parameter levelsPy1 and Py2 of the RF signal 156C during the states S1 and S2 are lowerthan the power parameter levels Px1 and Px2 of the RF signal 156A duringthe states S1 and S2. The power parameter level Px1 of the RF signal156A is the same as the power parameter level Px2 of the RF signal 156A.Similarly, the power parameter level Py1 of the RF signal 156C is thesame as the power parameter level Py2 of the RF signal 156C.

With reference to the graphs 150 and 154, during the state S1 of the RFsignal 156C, the RF signal 156C has the power parameter level of Py1 andhas the frequency level of fy1. Furthermore, at the transition timetst1, the RF signal 156C transitions from the state S1 to the state S2.During the state S2, the RF signal 156C has the power parameter level ofPy2. Also, during the state S2, the RF signal 156C has the frequencylevel of fy2. The frequency level of fy2 of the RF signal 156C isgreater than the frequency level of fy1 of the RF signal 156C. At thetransition time tst2, each RF signal 156A and 156C transitions from thestate S2 back to the state S1.

In some embodiments, the frequency level fx2 of the RF signal 156A islower than the frequency level fx1 of the RF signal 156A and thefrequency level fy1 of the RF signal 156C is greater than the frequencylevel fy2 of the RF signal 156C. In several embodiments, the frequencylevel fx2 of the RF signal 156A is greater than the frequency level fx1of the RF signal 156A and the frequency level fy1 of the RF signal 156Cis greater than the frequency level fy2 of the RF signal 156C. Invarious embodiments, the frequency level fx2 of the RF signal 156A islower than the frequency level fx1 of the RF signal 156A and thefrequency level fy1 of the RF signal 156C is lower than the frequencylevel fy2 of the RF signal 156C.

It should be noted that a duty cycle of the state S1 of the RF signal156C is the same as a duty cycle of the state S2 of the RF signal 156C.For example, the duty cycle of the state S1 of the RF signal 156C is 50%and the duty cycle of the state S2 of the RF signal 156C is 50%. Thestate S1 of the RF signal 156C occupies 50% of the cycle of the pulsedsignal 102 and the state S2 of the RF signal 156C occupies the remaining50% of the cycle of the pulsed signal 102.

In various embodiments, a duty cycle of the state S1 of the RF signal156C is different from a duty cycle of the state S2 of the RF signal156C. For example, the duty cycle of the state S1 of the RF signal 156Cis 25% and the duty cycle of the state S2 of the RF signal 156C is 75%.The state S1 of the RF signal 156C occupies 25% of the cycle of thepulsed signal 102 and the state S2 of the RF signal 156C occupies theremaining 75% of the cycle of the pulsed signal 102. As another example,the duty cycle of the state S1 of the RF signal 156C is a% and the dutycycle of the state S2 of the RF signal 156C is (100-a)%. The state S1 ofthe RF signal 156C occupies a% of the cycle of the pulsed signal 102 andthe state S2 of the RF signal 156C occupies the remaining (100-a)% ofthe cycle of the pulsed signal 102.

In some embodiments, the power parameter levels Py1 and Py2 of the RFsignal 156C are greater than the power parameter levels Px1 and Px2 ofthe RF signal 156A.

In various embodiments, the power parameter level of the RF signal 156Cis pulsed between the states S1 and S2 in additional to pulsing thefrequency level of the RF signal 156C. For example, Py1 of the RF signal156C during the state S1 is different from, such as greater than or lessthan, the power parameter level Py2 of the RF signal 156C during thestate S2.

In some embodiments, the power parameter level of the RF signal 156A ispulsed between the states S1 and S2 in addition to pulsing the frequencylevel of the RF signal 156A. For example, the power parameter level Px1of the RF signal 156A during the state S1 is different from, such asgreater than or less than, the power parameter level Px2 of the RFsignal 156A during the state S2.

It should be noted that the power parameter levels Px1, Px2, Py1, andPy2 are non-zero as illustrated in the graph 152. Moreover, thefrequency levels fx1, fx2, fy1, and fy2 are non-zero as illustrated inthe graph 152. Also, the power parameter levels Px1, Px2, Py1, and Py2are non-zero as illustrated in the graph 154. Moreover, the frequencylevels fx1, fx2, fy1, and fy2 are non-zero as illustrated in the graph154.

FIG. 2A is a block diagram of an embodiment of a plasma tool 200 forachieving peak ion energy enhancement with a low angular spread. Theplasma tool 200 is similar to the plasma tool 100 except that the plasmatool 200 is associated with three state operation of a pulsed signal 202rather than two state operation of the pulsed signal 102 (FIG. 1A). Theplasma tool 200 includes an RF generator RFGa, another RF generatorRFGb, the host computer 116, the IMN 104, the plasma chamber 108, theIMN 112, and the bias RF generator system 114. The RF generator RFGa isa low frequency RF generator, such as a 400 kHz RF generator or a 2 MHzRF generator, or a 13.56 MHz RF generator. The RF generator RFGb is ahigh frequency RF generator. Examples of the RF generator RFGb include a2 MHz, or a 13.56 MHz, or a 27 MHz, or a 60 MHz RF generator. The RFgenerator RFGb operates at a higher frequency than the RF generatorRFGa.

The RF generator RFGa includes the DSPx, the power controller PWRS1x,the power controller PWRS2x, yet another power controller PWRS3x, theauto frequency tuner AFTS1x, the auto frequency tuner AFTS2x, stillanother auto frequency tuner AFTS3x, the RF power supply Psx, and thedriver system 118.

The DSPx is coupled to the power controllers PWRS1x, PWRS2x, and PWRS3x,and to the auto-frequency tuners AFTS1x, AFTS2x, and AFTS3x. Moreover,the power controllers PWRS1x, PWRS2x, and PWRS3x and the auto-frequencytuners AFTS1x, AFTS2x, and AFTS3x are coupled to the driver system 118.The driver system 118 is coupled to the RF power supply Psx, which iscoupled to the RF cable 124 via an output of the RF generator RFGa.

The RF generator RFGb includes the DSPy, the power controller PWRS1y,the power controller PWRS2y, yet another power controller PWRS3y, theauto frequency tuner AFTS1y, and the auto frequency tuner AFTS2y. The RFgenerator RFGb further includes another auto frequency tuner AFTS3y, theRF power supply Psy, and the driver system 128. The DSPy is coupled tothe power controllers PWRS1y, PWRS2y, and PWRS3y, and to theauto-frequency tuners AFTS1y, AFTS2y, and AFTS3y. Moreover, the powercontrollers PWRS1y, PWRS2y, and PWRS3y and the auto-frequency tunersAFTS1y, AFTS2y, and AFTS3y are coupled to the driver system 132. Thedriver system 132 is coupled to the RF power supply Psy, which iscoupled to the RF cable 130 via an output of the RF generator RFGb.

A control circuit of the processor 132 is used to generate a pulsedsignal 202, e.g., a TTL signal, a digital pulsing signal, asquare-shaped waveform, a pulsed signal having three duty cycles for thethree states S1 through S3, etc. Examples of the control circuit of theprocessor 132 used to generate the pulsed signal 202 include a TTLcircuit.

The pulsed signal 202 includes the states S1, S2, and S3. For example,the state S1 of the pulsed signal 202 has a logic level of one during aportion of a clock cycle of a clock signal 204 and a logic level of zeroduring another portion of the clock cycle, the state S2 of the pulsedsignal 202 has a logic level of one during a portion of the clock cycleand a logic level of zero during another portion of the clock cycle, thestate S3 of the pulsed signal 202 has a logic level of one during aportion of the clock cycle and a logic level of zero during anotherportion of the clock cycle. In various embodiments, the states S1, S2,and S3 execute once during a clock cycle of the pulsed signal 202 andrepeat with multiple clock cycles. For example, the clock cycle includesthe states S1 through S3 and another clock cycle of the clock signal 204includes the states S1 through S3. To illustrate, during a portion of aperiod of a clock cycle, the state S1 is executed, during another periodof the clock cycle, the state S2 is executed, and during remainingportion of the period of the clock cycle, the state S3 is executed.

In some embodiments, each of the states S1 through S3 has a one-thirdduty cycle. In several embodiments, each of the states S1 through S3 hasa different duty cycle than a duty cycle of any of remaining of thestates S1 through S3. For example, the state S1 has an a% duty cycle,the state S2 has a duty cycle of b%, and the state S3 has a duty cycleof (100-a-b)%, where a and b are positive integers and where a is adifferent number than b.

In various embodiments, instead of the control circuit of the processor132 for generating the pulsed signal 202, a clock source, e.g., acrystal oscillator, etc., is used to generate an analog clock signal,which is converted by an analog-to-digital converter into a digitalsignal similar to the pulsed signal 202. For example, the crystaloscillator is made to oscillate in an electric field by applying avoltage to an electrode near the crystal oscillator. To illustrate, thecrystal oscillator oscillates at a first frequency during a firstportion of the clock cycle of the clock signal 204, at a secondfrequency during a second portion of the clock cycle of the clock signal204, and at a third frequency during a remaining portion of the clockcycle of the clock signal 204. The third frequency is different from thesecond frequency, which is different from the first frequency. In someembodiments, the first frequency is the same as the second frequency butis different from the third frequency. In various embodiments, the firstfrequency is the same as the third frequency but is different from thesecond frequency. In various embodiments, instead of the processor 132,a digital clock source generates the pulsed signal 202.

The processor 132 accesses a recipe from the memory device 144. Examplesof the recipe include a power parameter set point to be applied to theRF generator RFGa for the state S1, a power parameter set point to beapplied to the RF generator RFGa for the state S2, a power parameter setpoint to be applied to the RF generator RFGa for the state S3, afrequency set point to be applied to the RF generator RFGa for the stateS1, a frequency set point to be applied to the RF generator RFGa for thestate S2, a frequency set point to be applied to the RF generator RFGafor the state S3, a power parameter set point to be applied to the RFgenerator RFGb for the state S1, a power parameter set point to beapplied to the RF generator RFGb for the state S2, a power parameter setpoint to be applied to the RF generator RFGb for the state S3, afrequency set point to be applied to the RF generator RFGb for the stateS1, a frequency set point to be applied to the RF generator RFGb for thestate S2, a frequency set point to be applied to the RF generator RFGbfor the state S3, a chemistry of the one or more process gases, or acombination thereof.

The processor 132 sends an instruction with the pulsed signal 202 to theDSPx via the cable 146. The instruction sent to the DSPx via the cable146 has information regarding the pulsed signal 202, the power parameterset point to be applied to the RF generator RFGa for the state S1, thepower parameter set point to be applied to the RF generator RFGa for thestate S2, the power parameter set point to be applied to the RFgenerator RFGa for the state S3, the frequency set point to be appliedto the RF generator RFGa for the state S1, the frequency set point to beapplied to the RF generator RFGa for the state S2, and the frequency setpoint to be applied to the RF generator RFGa for the state S3. Theinformation regarding the pulsed signal 202 indicates to the DSPx thatthe RF signal to be generated by the RF generator RFGa is to transitionfrom the state S1 to the state S2 at a transition time ts1 of the clockcycle, that the RF signal is to transition from the state S2 to thestate S3 at a transition time ts2 of the clock cycle, and that the RFsignal is to transition from the state S3 to the state S1 at atransition time ts3 of the clock cycle. The DSPx determines from theinstruction that the power parameter set point for the state S1 is to beapplied during the state S1 of the pulsed signal 202, the powerparameter set point for the state S2 is to be applied during the stateS2 of the pulsed signal 202, the power parameter set point for the stateS3 is to be applied during the state S3 of the pulsed signal 202, thefrequency set point for the state S1 is to be applied during the stateS1 of the pulsed signal 202, the frequency set point for the state S2 isto be applied during the state S2 of the pulsed signal 202, and thefrequency set point for the state S3 is to be applied during the stateS3 of the pulsed signal 202. Moreover, the DSPx determines from theinstruction and the pulsed signal 202, that the RF signal to begenerated by the RF generator RFGa is to transition from the state S1 tothe state S2 at the transition time ts1 of the clock cycle, that the RFsignal is to transition from the state S2 to the state S3 at thetransition time ts2 of the clock cycle, and that the RF signal is totransition from the state S3 to the state S1 at the transition time ts3of the clock cycle. The transition times ts1 through ts3 repeat for eachclock cycle of the clock signal 204.

At the transition time ts3 of the clock cycle of the clock signal 204,the DSPx sends the power parameter set point for the state S1 to thepower controller PWRS1x. Similarly, at the transition time ts1 of theclock cycle of the clock signal 204, the DSPx sends the power parameterset point for the state S2 to the power controller PWRS2x. Also, at thetransition time ts2 of the clock cycle of the clock signal 204, the DSPxsends the power parameter set point for the state S3 to the powercontroller PWRS3x. Moreover, at the transition time ts3 of the clockcycle, the DSPx sends the frequency set point for the state S1 to theauto-frequency tuner AFTS1x. Also, at the transition time ts1 of theclock cycle, the DSPx sends the frequency set point for the state S2 tothe auto-frequency tuner AFTS2x. Moreover, at the transition time ts2 ofthe clock cycle, the DSPx sends the frequency set point for the state S3to the auto-frequency tuner AFTS3x.

Upon receiving the power parameter set point for the state S1, the powercontroller PWRS1x determines an amount of current corresponding to thepower parameter set point for the state S1. Based on the amount ofcurrent that is to be generated by the driver system 118 during thestate S1, the power controller PWRS1x generates a command signal andsends the command signal to the driver system 118. For the state S1, inresponse to receiving the command signal, the driver system 118generates and sends a current signal having the amount of current to theRF power supply Psx. The RF power supply Psx, upon receiving the currentsignal generates the RF signal having the power parameter set point forthe state S1 and supplies the RF signal via the output of the RFgenerator RFGa and the RF cable 124 to the input of the IMN 104. Thepower parameter set point for the state S1 is maintained during thestate S1 by the RF power supply Psx of the RF generator RFGa.

Similarly, upon receiving the power parameter set point for the stateS2, the power controller PWRS2x determines an amount of currentcorresponding to the power parameter set point for the state S2. Basedon the amount of current that is to be generated by the driver system118 during the state S2, the power controller PWRS2x generates a commandsignal and sends the command signal to the driver system 118. For thestate S2, in response to receiving the command signal, the driver system118 generates and sends a current signal having the amount of current tothe RF power supply Psx. The RF power supply Psx, upon receiving thecurrent signal generates the RF signal having the power parameter setpoint for the state S2 and supplies the RF signal via the output of theRF generator RFGa and the RF cable 124 to the input of the IMN 104. Thepower parameter set point for the state S2 is maintained during thestate S2 by the RF power supply Psx of the RF generator RFGa.

Moreover, upon receiving the power parameter set point for the state S3,the power controller PWRS3x determines an amount of currentcorresponding to the power parameter set point for the state S3. Basedon the amount of current that is to be generated by the driver system118 during the state S3, the power controller PWRS3x generates a commandsignal and sends the command signal to the driver system 118. For thestate S3, in response to receiving the command signal, the driver system118 generates and sends a current signal having the amount of current tothe RF power supply Psx. The RF power supply Psx, upon receiving thecurrent signal generates the RF signal having the power parameter setpoint for the state S3 and supplies the RF signal via the output of theRF generator RFGa and the RF cable 124 to the input of the IMN 104. Thepower parameter set point for the state S3 is maintained during thestate S3 by the RF power supply Psx of the RF generator RFGa.

Moreover, upon receiving the frequency set point for the state S1, theauto-frequency tuner AFTS1x determines an amount of currentcorresponding to the frequency set point for the state S1. Based on theamount of current that is to be generated by the driver system 118during the state S1, the auto-frequency tuner AFTS1x generates a commandsignal and sends the command signal to the driver system 118. For thestate S1, in response to receiving the command signal, the driver system118 generates and sends a current signal having the amount of current tothe RF power supply Psx. The RF power supply Psx, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S1 and supplies the RF signal via the output of the RFgenerator RFGa and the RF cable 124 to the input of the IMN 104. Thefrequency set point for the state S1 is maintained during the state S1by the RF power supply Psx of the RF generator RFGa. The RF signalhaving the power parameter set point for the state S1 and the frequencyset point for the state S1 is the RF signal generated by the RFgenerator RFGa during the state S1.

Similarly, upon receiving the frequency set point for the state S2, theauto-frequency tuner AFTS2x determines an amount of currentcorresponding to the frequency set point for the state S2. Based on theamount of current that is to be generated by the driver system 118during the state S2, the auto-frequency tuner AFTS2x generates a commandsignal and sends the command signal to the driver system 118. For thestate S2, in response to receiving the command signal, the driver system118 generates and sends a current signal having the amount of current tothe RF power supply Psx. The RF power supply Psx, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S2 and supplies the RF signal via the output of the RFgenerator RFGa and the RF cable 124 to the input of the IMN 104. Thefrequency set point for the state S2 is maintained during the state S2by the RF power supply Psx of the RF generator RFGa. The RF signalhaving the power parameter set point for the state S2 and the frequencyset point for the state S2 is the RF signal generated by the RFgenerator RFGa during the state S2.

Moreover, upon receiving the frequency set point for the state S3, theauto-frequency tuner AFTS3x determines an amount of currentcorresponding to the frequency set point for the state S3. Based on theamount of current that is to be generated by the driver system 118during the state S3, the auto-frequency tuner AFTS3x generates a commandsignal and sends the command signal to the driver system 118. For thestate S3, in response to receiving the command signal, the driver system118 generates and sends a current signal having the amount of current tothe RF power supply Psx. The RF power supply Psx, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S3 and supplies the RF signal via the output of the RFgenerator RFGa and the RF cable 124 to the input of the IMN 104. Thefrequency set point for the state S3 is maintained during the state S3by the RF power supply Psx of the RF generator RFGa. The RF signalhaving the power parameter set point for the state S3 and the frequencyset point for the state S3 is the RF signal generated by the RFgenerator RFGa during the state S3.

The processor 132 sends an instruction with the pulsed signal 202 to theDSPy via the cable 148. The instruction sent to the DSPy via the cable148 has information regarding the pulsed signal 202, the power parameterset point to be applied to the RF generator RFGb for the state S1, thepower parameter set point to be applied to the RF generator RFGb for thestate S2, the power parameter set point to be applied to the RFgenerator RFGb for the state S3, the frequency set point to be appliedto the RF generator RFGb for the state S1, the frequency set point to beapplied to the RF generator RFGb for the state S2, and the frequency setpoint to be applied to the RF generator RFGb for the state S3. Theinformation regarding the pulsed signal 202 indicates to the DSPy thatthe RF signal to be generated by the RF generator RFGb is to transitionfrom the state S1 to the state S2 at the transition time ts1 of theclock cycle of the clock signal 204, that the RF signal is to transitionfrom the state S2 to the state S3 at the transition time ts2 of theclock cycle, and that the RF signal is to transition from the state S3to the state S1 at the transition time ts3 of the clock cycle. The DSPyparses the instruction and determines from the instruction that thepower parameter set point for the state S1 is to be applied during thestate S1 of the pulsed signal 202, the power parameter set point for thestate S2 is to be applied during the state S2 of the pulsed signal 202,the power parameter set point for the state S3 is to be applied duringthe state S3 of the pulsed signal 202, the frequency set point for thestate S1 is to be applied during the state S1 of the pulsed signal 202,the frequency set point for the state S2 is to be applied during thestate S2 of the pulsed signal 202, and the frequency set point for thestate S3 is to be applied during the state S3 of the pulsed signal 202.Moreover, the DSPy determines from the instruction that the RF signal tobe generated by the RF generator RFGb is to transition from the state S1to the state S2 at the transition time ts1 of the clock cycle, that theRF signal is to transition from the state S2 to the state S3 at thetransition time ts2 of the clock cycle, and that the RF signal is totransition from the state S3 to the state S1 at the transition time ts3of the clock cycle.

At the transition time ts3 of the clock cycle of the clock signal 204,the DSPy sends the power parameter set point for the state S1 to thepower controller PWRS1y. Similarly, at the transition time ts1 of theclock cycle of the clock signal 204, the DSPy sends the power parameterset point for the state S2 to the power controller PWRS2y. Also, at thetransition time ts2 of the clock cycle of the clock signal 204, the DSPysends the power parameter set point for the state S3 to the powercontroller PWRS3y. Moreover, at the transition time ts3 of the clockcycle, the DSPy sends the frequency set point for the state S1 to theauto-frequency tuner AFTS1y. Also, at the transition time ts1 of theclock cycle, the DSPy sends the frequency set point for the state S2 tothe auto-frequency tuner AFTS2y. Moreover, at the transition time ts2 ofthe clock cycle, the DSPy sends the frequency set point for the state S3to the auto-frequency tuner AFTS3y.

Upon receiving the power parameter set point for the state S1, the powercontroller PWRS1y determines an amount of current corresponding to thepower parameter set point for the state S1. Based on the amount ofcurrent that is to be generated by the driver system 128 during thestate S1, the power controller PWRS1y generates a command signal andsends the command signal to the driver system 128. For the state S1, inresponse to receiving the command signal, the driver system 128generates and sends a current signal having the amount of current to theRF power supply Psy. The RF power supply Psy, upon receiving the currentsignal generates the RF signal having the power parameter set point forthe state S1 and supplies the RF signal via the output of the RFgenerator RFGb and the RF cable 130 to the other input of the IMN 104.The power parameter set point for the state S1 is maintained during thestate S1 by the RF power supply Psy.

Similarly, upon receiving the power parameter set point for the stateS2, the power controller PWRS2y determines an amount of currentcorresponding to the power parameter set point for the state S2. Basedon the amount of current that is to be generated by the driver system128 during the state S2, the power controller PWRS2y generates a commandsignal and sends the command signal to the driver system 128. For thestate S2, in response to receiving the command signal, the driver system128 generates and sends a current signal having the amount of current tothe RF power supply Psy. The RF power supply Psy, upon receiving thecurrent signal generates the RF signal having the power parameter setpoint for the state S2 and supplies the RF signal via the output of theRF generator RFGb and the RF cable 130 to the other input of the IMN104. The power parameter set point for the state S2 is maintained duringthe state S2 by the RF power supply Psy.

Moreover, upon receiving the power parameter set point for the state S3,the power controller PWRS3y determines an amount of currentcorresponding to the power parameter set point for the state S3. Basedon the amount of current that is to be generated by the driver system128 during the state S3, the power controller PWRS3y generates a commandsignal and sends the command signal to the driver system 128. For thestate S3, in response to receiving the command signal, the driver system128 generates and sends a current signal having the amount of current tothe RF power supply Psy. The RF power supply Psy, upon receiving thecurrent signal generates the RF signal having the power parameter setpoint for the state S3 and supplies the RF signal via the output of theRF generator RFGb and the RF cable 130 to the other input of the IMN104. The power parameter set point for the state S3 is maintained duringthe state S3 by the RF power supply Psy.

Moreover, upon receiving the frequency set point for the state S1, theauto-frequency tuner AFTS1y determines an amount of currentcorresponding to the frequency set point for the state S1. Based on theamount of current that is to be generated by the driver system 128during the state S1, the auto-frequency tuner AFTS1y generates a commandsignal and sends the command signal to the driver system 128. For thestate S1, in response to receiving the command signal, the driver system128 generates and sends a current signal having the amount of current tothe RF power supply Psy. The RF power supply Psy, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S1 and supplies the RF signal via the output of the RFgenerator RFGb and the RF cable 130 to the other input of the IMN 104.The frequency set point for the state S1 is maintained during the stateS1 by the RF power supply Psy. The RF signal having the power parameterset point for the state S1 and the frequency set point for the state S1is the RF signal generated by the RF generator RFGb during the state S1.

Similarly, upon receiving the frequency set point for the state S2, theauto-frequency tuner AFTS2y determines an amount of currentcorresponding to the frequency set point for the state S2. Based on theamount of current that is to be generated by the driver system 128during the state S2, the auto-frequency tuner AFTS2y generates a commandsignal and sends the command signal to the driver system 132. For thestate S2, in response to receiving the command signal, the driver system132 generates and sends a current signal having the amount of current tothe RF power supply Psy. The RF power supply Psy, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S2 and supplies the RF signal via the output of the RFgenerator RFGb and the RF cable 130 to the other input of the IMN 104.The frequency set point for the state S2 is maintained during the stateS2 by the RF power supply Psy. The RF signal having the power parameterset point for the state S2 and the frequency set point for the state S2is the RF signal generated by the RF generator RFGb during the state S2.

Moreover, upon receiving the frequency set point for the state S3, theauto-frequency tuner AFTS3y determines an amount of currentcorresponding to the frequency set point for the state S3. Based on theamount of current that is to be generated by the driver system 128during the state S3, the auto-frequency tuner AFTS3y generates a commandsignal and sends the command signal to the driver system 128. For thestate S3, in response to receiving the command signal, the driver system128 generates and sends a current signal having the amount of current tothe RF power supply Psy. The RF power supply Psy, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S3 and supplies the RF signal via the output of the RFgenerator RFGb and the RF cable 130 to the other input of the IMN 104.The frequency set point for the state S3 is maintained during the stateS3 by the RF power supply Psy. The RF signal having the power parameterset point for the state S3 and the frequency set point for the state S3is the RF signal generated by the RF generator RFGb during the state S3.

The input of the IMN 104 receives, at the input, the RF signal generatedby the RF generator RFGa via the RF cable 124 from the output of the RFgenerator RFGa, receives, at the other input, the RF signal generated bythe RF generator RFGb via the RF cable 130 from the output of the RFgenerator RFGb, and matches an impedance of the load coupled to theoutput of the IMN 104 with an impedance of the source coupled to theinputs of the IMN 104 to generate a modified RF signal at the output ofthe IMN 104. The modified RF signal is sent via the RF transmission line126 to the upper electrode 106. When the one or more process gases aresupplied between the upper electrode 108 and the chuck 110, the modifiedRF signal is supplied to the lower electrode 120, and the output RFsignal is supplied to the chuck 110, the one or more process gases areignited to generate plasma within the plasma chamber 108 or the plasmais maintained within the plasma chamber 108.

In various embodiments, the power controllers PWRS1x, PWRS2x, andPWRS3x, and the auto-frequency tuners AFTS1x, AFTS2x, and AFTS3x aremodules, e.g., portions, etc., of a computer program that is executed bythe DSPx of the RF generator RFGa.

In several embodiments, the power controllers PWRS1x, PWRS2x, andPWRS3x, and the auto-frequency tuners AFTS1x, AFTS2x, and AFTS3x areseparate integrated circuits that are coupled to an integrated circuitof the DSPx of the RF generator RFGa. For example, the power controllerPWRS1x is a first integrated circuit of the RF generator RFGa, the powercontroller PWRS2x is a second integrated circuit of the RF generatorRFGa, the power controller PWRS3x is a third integrated circuit of theRF generator RFGa, the auto-frequency tuner AFTS1x is a fourthintegrated circuit of the RF generator RFGa, the auto-frequency tunerAFTS2x is a fifth integrated circuit of the RF generator RFGa, theauto-frequency tuner AFTS3x is a sixth integrated circuit of the RFgenerator RFGa, and the DSPx is a seventh integrated circuit of the RFgenerator RFGa. Each of the first through sixth integrated circuit ofthe RF generator RFGa is coupled to the seventh integrated circuit ofthe RF generator RFGa.

In some embodiments, the power controllers PWRS1y, PWRS2y, and PWRS3y,and the auto-frequency tuners AFTS1y, AFTS2y, and AFTS3y are modules,e.g., portions, etc., of a computer program that is executed by the DSPyof the RF generator RFGb.

In various embodiments, the power controllers PWRS1y, PWRS2y, andPWRS3y, and the auto-frequency tuners AFTS1y, AFTS2y, and AFTS3y areseparate integrated circuits that are coupled to an integrated circuitof the DSPy of the RF generator RFGb. For example, the power controllerPWRS1y is a first integrated circuit of the RF generator RFGb, the powercontroller PWRS2y is a second integrated circuit of the RF generatorRFGb, the power controller PWRS3y is a third integrated circuit of theRF generator RFGb, the auto-frequency tuner AFTS1y is a fourthintegrated circuit of the RF generator RFGb, the auto-frequency tunerAFTS2y is a fifth integrated circuit of the RF generator RFGb, theauto-frequency tuner AFTS3y is a sixth integrated circuit of the RFgenerator RFGb, and the DSPy is a seventh integrated circuit of the RFgenerator RFGb. Each of the first through sixth integrated circuit ofthe RF generator RFGb is coupled to the seventh integrated circuit ofthe RF generator RFGb.

In some embodiments, an example of the state S3 of the RF signalincludes the power parameter set point for the state S3 and thefrequency set point for the state S3. The power parameter set point forthe state S3 is an operational power parameter set point, which is apower parameter level, such as an envelope or a zero-to-peak magnitude,of power amounts or voltage amounts of the RF signal during the stateS3. The frequency set point for the state S3 is an operational frequencyset point, which is a frequency level, such as an envelope or azero-to-peak magnitude, of frequency values of the RF signal during thestate S3.

In various embodiments, the clock signal 204 is generated by theprocessor 132 or by a clock source, examples of which are providedabove. In some embodiments, the clock signal 204 is sent from theprocessor 132 via the cable 146 to the DSPx of the RF generator RFGa andvia the cable 148 to the DSPy of the RF generator RFGb.

In some embodiments, instead of the pulsed signal 202 being sent fromthe processor 132 to the RF generators RFGa and RFGb, the pulsed signal202 is sent from a master RF generator to a slave RF generator, such asthe RF generator RFGb. An example of the master RF generator includesthe RF generator RFGa. To illustrate, the digital signal processor DSPxof the RF generator RFGa receives the pulsed signal 202 from theprocessor 132 and sends the pulsed signal 202 via a cable, such as aparallel transfer cable, a serial transfer cable, or a USB cable, to thedigital signal processor DSPy of the RF generator RFGb.

FIG. 2B is a diagram of embodiments of graphs 210, 212, and 214 toillustrate the states S1, S2, and S2 of the RF signal, such as an RFsignal 216A, generated and supplied by the RF generator RFGa and of theRF signal, such as an RF signal 216B, generated and supplied by the RFgenerator RFGb. The graph 210 plots a logic level of the clock signal204 versus the time t. Similarly, the graph 212 plots a logic level ofthe pulsed signal 202 versus the time t.

A time period t1 is a period of time during the clock cycle of the clocksignal 204 for which the state S1 of the RF signals generated by the RFgenerators RFGa and RFGb is maintained. Similarly, a time period t2 is aperiod of time during the clock cycle of the clock signal 204 for whichthe state S2 of the RF signals generated by the RF generators RFGa andRFGb is maintained. Also, a time period t3 is a period of time duringthe clock cycle of the clock signal 204 for which the state S3 of the RFsignals generated by the RF generators RFGa and RFGb is maintained. Forexample, the time period t1 occupies a portion of the clock cycle, thetime period t2 occupies another portion of the clock cycle, and the timeperiod t3 occupies the remaining portion of the clock cycle. The clockcycle of the clock signal 204 is made of the time periods t1 through t3and repeats to create multiple clock cycles of the clock signal 204.

During the time period t1, the pulsed signal 202 pulses from a logiclevel 1 to a logic level 0. The logic level is an example of a highlogic level and the logic level 0 is an example of a low logic level.During the time period t1, the RF signals generated by the RF generatorsRFGa and RFGb are controlled to maintain the state S1.

At the transition time ts1 of the clock cycle at which the pulsed signal202 transitions from the logic level 0 to the logic level 1, the RFsignals generated by the RF generators RFGa and RFGb are controlled totransition from the state S1 to the state S2. The transition time ts1occurs after the time period t1.

The time period t2 occurs after the transition time ts1. During the timeperiod t2, the pulsed signal 202 pulses from the logic level 1 to thelogic level 0. Moreover, during the time period t2, the RF signalsgenerated by the RF generators RFGa and RFGb are controlled to maintainthe state S2.

At the transition time ts2 of the clock cycle at which the pulsed signal202 transitions from the logic level 0 to the logic level 1, the RFsignals generated by the RF generators RFGa and RFGb are controlled totransition from the state S2 to the state S3. The transition time ts2occurs after the time period t2.

The time period t3 occurs after the transition time ts2. During the timeperiod t3, the pulsed signal 202 pulses from the logic level 1 to thelogic level 0. Moreover, during the time period t3, the RF signalsgenerated by the RF generators RFGa and RFGb are controlled to maintainthe state S3.

At the transition time ts3 of the clock cycle at which the pulsed signal102 transitions from the logic level 0 to the logic level 1, the RFsignals generated by the RF generators RFGa and RFGb are controlled totransition from the state S3 to the state S1. The transition time ts3occurs after the time period t3. The time period t1 repeats after thetransition time ts3 during a consecutive clock cycle of the clock signal204. The time period t1 during the consecutive clock cycle of the clocksignal 204 is again followed by the time periods t2 and t3 of theconsecutive clock cycle of the clock signal 204. The consecutive clockcycle of the clock signal 204 is consecutive, such as continuouslyfollows or sequentially follows, the clock cycle of the clock signal204. The transition times ts1 through ts3 and the time periods t1through t3 repeat for the consecutive clock cycle. Moreover, thetransition times ts1 through ts3 and the time periods t1 through t3repeat for following cycles of the clock signal 204 that repeat afterthe consecutive cycle.

The states S1 through S3 of the RF signals 216A and 216B repeat insynchronization with each cycle of the clock signal 204. For example,the states S1 through S3 of the RF signal 216A occur during the clockcycle of the clock signal 204 and the states S1 through S3 of the RFsignal 216A repeat during the consecutive clock cycle of the clocksignal 204. As another example, the states S1 through S3 of the RFsignal 216B occur during the clock cycle of the clock signal 204 and thestates S1 through S3 of the RF signal 216B repeat during the consecutiveclock cycle of the clock signal 204.

The RF signal 216A has a frequency level of f1x during the state S1 andhas a power parameter level of P1x during the state S1. Moreover, the RFsignal 216B has a frequency level fly of zero during the state S1 andhas a power parameter level of P1y of zero during the state S1.

Similarly, the RF signal 216A has a frequency level of f2x during thestate S2 and has a power parameter level of P2x during the state S2. Thefrequency level f2x is the same as that of the frequency level f1x andthe power parameter level P2x is the same as that of the power parameterlevel P1x. Moreover, the RF signal 216B has a frequency level of f2yduring the state S2 and has a power parameter level of P2y during thestate S2. The power parameter level P2y is the same as the powerparameter level P2x. The frequency level f2y is greater than thefrequency level f2x.

Similarly, the RF signal 216A has a frequency level of f3x of zeroduring the state S3 and has a power parameter level P3x of zero duringthe state S3. Moreover, the RF signal 216B has a frequency level of f3yduring the state S3 and has a power parameter level of P3y during thestate S3. The frequency level f3y is lower than the frequency level f2yand is greater than the frequency level f2x. Moreover, the powerparameter level P3y is the same as the power parameter level P2y.

It should be noted that the power parameter levels P1x, P2x, P2y, andP3y are non-zero as illustrated in the graph 214. Similarly, thefrequency levels f1x, f2x, f2y, and f3y are non-zero as illustrated inthe graph 214.

In some embodiments, the power parameter levels P2y and P3y are not thesame as, such as lower than or greater than, the power parameter levelsP1x and P2x.

In various embodiments, the frequency level f3y is greater than thefrequency level f2y. In several embodiments, the frequency level f3y isthe same as the frequency level f2y. In some embodiments, the powerparameter level P2x is not the same as, such as is greater than or lowerthan, the power parameter level P1x. In various embodiments, the powerparameter level P2y is not the same as, such as is greater than or lowerthan, the power parameter level P3y.

In some embodiments, the frequency level f2x is not the same as, such asis greater than or lower than, the frequency level f1x. In variousembodiments, the frequency level f1x and the power parameter level P1xare zero. In some embodiments, the frequency level f2x and the powerparameter level P2x are zero. In several embodiments, the frequencylevel f3y and the power parameter level P3y are zero. In someembodiments, the frequency level f2y and the power parameter level P2yare zero.

In some embodiments, each of the states S1 through S3 of the RF signal216A or the RF signal 216B has a one-third duty cycle. In severalembodiments, each of the states S1 through S3 of an RF signal, such asthe RF signal 216A or the RF signal 216B, has a different duty cyclethan a duty cycle of any of remaining of the states S1 through S3 of theRF signal. For example, the state S1 has of the RF signal an a% dutycycle, the state S2 of the RF signal has a duty cycle of b%, and thestate S3 of the RF signal as a duty cycle of (100-a-b)%. To illustrate,a duty cycle of the state S1 of the RF signal is different from a dutycycle of the state S2 of the RF signal. As another illustration, a dutycycle of the state S1 of the RF signal is different from a duty cycle ofthe state S2 of the RF signal and the duty cycle of the states S1 of theRF signal is the same as a duty cycle of the state S3 of the RF signal.As another illustration, a duty cycle of the state S1 of the RF signalis different from a duty cycle of the state S3 of the RF signal. As yetanother illustration, a duty cycle of the state S1 of the RF signal isdifferent from a duty cycle of the state S3 of the RF signal and theduty cycle of the state S1 of the RF signal is the same as a duty cycleof the state S2 of the RF signal. As yet another illustration, a dutycycle of the state S2 of the RF signal is different from a duty cycle ofthe state S3 of the RF signal. As another illustration, a duty cycle ofthe state S2 of the RF signal is different from a duty cycle of thestate S3 of the RF signal and the duty cycle of the state S2 of the RFsignal is the same as a duty cycle of the state S1 of the RF signal.

It should be noted that the RF generator RFGa is controlled to operateat the frequency level f2x during the state S2. The power parameter ofthe RF signal generated by the RF generator RFGa during the state S2 isadded to the power parameter of the RF signal generated by the RFgenerator RFGb during the state S3. The plasma sheath 123 of plasmaformed within the plasma chamber 108 acts as the capacitor, whichcharges during the state S2 from the power parameter level P2xassociated with the frequency level f2x and discharges during the stateS3. The addition of the power parameters and the discharging of thecapacitor increases ion energy of ions of plasma within the plasmachamber 108 during the state S3 and decreases an angular spread of theion energy during the state S3. For example, a vertical directionalityof plasma within the plasma chamber 108 increases during the state S3with the addition of the power parameters during the state S3.

FIG. 2C is a diagram of embodiments of the graphs 210, 212, and a graph218 to illustrate the states S1, S2, and S2 of the RF signal, such as anRF signal 220A, generated and supplied by the RF generator RFGa and ofthe RF signal, such as an RF signal 220B, generated and supplied by theRF generator RFGb.

The states S1 through S3 of the RF signals 220A and 220B repeat insynchronization with each cycle of the clock signal 204. For example,the states S1 through S3 of the RF signal 220A occur during the clockcycle of the clock signal 204 and the states S1 through S3 of the RFsignal 220A repeat during the consecutive clock cycle of the clocksignal 204. As another example, the states S1 through S3 of the RFsignal 220B occur during the clock cycle of the clock signal 204 and thestates S1 through S3 of the RF signal 220B repeat during the consecutiveclock cycle of the clock signal 204.

The RF signal 220A has a frequency level f1x of zero during the state S1and has a power parameter level P1x of zero during the state S1.Moreover, the RF signal 220B has a frequency level fly of zero duringthe state S1 and has a power parameter level of P1y of zero during thestate S1.

Similarly, the RF signal 220A has a frequency level of f2x during thestate S2 and has a power parameter level of P2x during the state S2.Moreover, the RF signal 220B has a frequency level of f2y during thestate S2 and has a power parameter level of P2y during the state S2. Thepower parameter level P2y is the same as the power parameter level P2xand the frequency level f2y is greater than the frequency level f2x.

Similarly, the RF signal 220A has a frequency level of f3x during thestate S3 and has a power parameter level P3x during the state S3. Thefrequency level f3x is greater than the frequency level f2x and thepower parameter level P3x is the same as the power parameter level P2x.Moreover, the RF signal 220B has a frequency level of f3y during thestate S3 and has a power parameter level of P3y during the state S3. Thefrequency level f3y is lower than the frequency level f2y. Moreover, thepower parameter level P3y is the same as the power parameter level P2y.Also, the frequency level f3x is greater than the frequency level f2x.

In some embodiments, the power parameter levels P2y and P3y are not thesame as, such as lower than or greater than, the power parameter levelsP2x and P3x.

In various embodiments, the frequency level f3x is the same as thefrequency level f2x. In several embodiments, the frequency level f3x islower than the frequency level f2x. In various embodiments, thefrequency level f3y is greater than the frequency level f2y. In severalembodiments, the frequency level f3y is the same as the frequency levelf2y.

In some embodiments, the power parameter level P2x is not the same as,such as is greater than or lower than, the power parameter level P3x. Invarious embodiments, the power parameter level P2y is not the same as,such as is greater than or lower than, the power parameter level P3y.

In some embodiments, the frequency level f2x and the power parameterlevel P2x are zero. In various embodiments, the frequency level f3x andthe power parameter level P3x are zero. In some embodiments, thefrequency level f2y and the power parameter level P2y are zero. Inseveral embodiments, the frequency level f3y and the power parameterlevel P3y are zero.

In some embodiments, each of the states S1 through S3 of the RF signal220A or the RF signal 220B has a one-third duty cycle. In severalembodiments, each of the states S1 through S3 of an RF signal, such asthe RF signal 220A or the RF signal 220B, has a different duty cyclethan a duty cycle of any of remaining of the states S1 through S3 of theRF signal. For example, the state S1 has of the RF signal an a% dutycycle, the state S2 of the RF signal has a duty cycle of b%, and thestate S3 of the RF signal as a duty cycle of (100-a-b)%.

It should be noted that the RF generator RFGa is controlled to operateat the frequency level f2x during the state S2. The power parameter ofthe RF signal generated by the RF generator RFGa during the state S2 isadded to the power parameter of the RF signal generated by the RFgenerator RFGb during the state S3. The plasma sheath 123 of plasmaformed within the plasma chamber 108 acts as the capacitor, whichcharges during the state S2 from the power parameter level P2xassociated with the frequency level f2x and discharges during the stateS3. The addition of the power parameters and the discharging of thecapacitor increases ion energy of ions of plasma within the plasmachamber 108 during the state S3 and decreases an angular spread of theion energy during the state S3. For example, a vertical directionalityof plasma within the plasma chamber 108 increases during the state S3with the addition of the power parameters during the state S3.

It should be noted that the power parameter levels P2x, P3x, P2y, andP3y are non-zero as illustrated in the graph 218. Moreover, thefrequency levels f2x, f3x, f2y, and f3y are non-zero as illustrated inthe graph 218.

FIG. 2D is a diagram of embodiments of the graphs 210, 212, and a graph222 to illustrate the states S1, S2, and S2 of the RF signal, such as anRF signal 224A, generated and supplied by the RF generator RFGa and ofthe RF signal, such as an RF signal 224B, generated and supplied by theRF generator RFGb.

The states S1 through S3 of the RF signals 224A and 224B repeat insynchronization with each cycle of the clock signal 204. For example,the states S1 through S3 of the RF signal 224A occur during the clockcycle of the clock signal 204 and the states S1 through S3 of the RFsignal 224A repeat during the consecutive clock cycle of the clocksignal 204. As another example, the states S1 through S3 of the RFsignal 224B occur during the clock cycle of the clock signal 204 and thestates S1 through S3 of the RF signal 224B repeat during the consecutiveclock cycle of the clock signal 204.

The RF signal 224A has a frequency level f1x of zero during the state S1and has a power parameter level P1x of zero during the state S1.Moreover, the RF signal 224B has a frequency level fly of zero duringthe state S1 and has a power parameter level P1y of zero during thestate S1.

Similarly, the RF signal 224A has a frequency level f2x during the stateS2 and has a power parameter level P2x of zero during the state S2.Moreover, the RF signal 224B has a frequency level of f2y during thestate S2 and has a power parameter level of P2y during the state S2. Thefrequency level f2y of the RF signal 224B is greater than the frequencylevel f2x of the RF signal 224A during the state S2 and the powerparameter level P2y of the RF signal 224B is the same as the powerparameter level P2x of the RF signal 224A during the state S2.

Similarly, the RF signal 224A has a frequency level f3x of zero duringthe state S3 and has a power parameter level P3x of zero during thestate S3. Moreover, the RF signal 224B has a frequency level of f3yduring the state S3 and has a power parameter level of P3y during thestate S3. The frequency level f3y of the RF signal 224B during the stateS3 is the same as the frequency level f2y of the RF signal 224B duringthe state S2. Moreover, the power parameter level P3y of the RF signal224B during the state S3 is the same as the power parameter level P2y ofthe RF signal 224B during the state S2.

In some embodiments, the power parameter levels P2y and P3y are not thesame as, such as lower than or greater than, the power parameter levelP2x.

In various embodiments, the frequency level f3y is not the same as, suchas is greater than or lower than, the frequency level f2y. In severalembodiments, the frequency level f2y and the power parameter level P2yare zero. In various embodiments, the frequency level f3y and the powerparameter level P3y are zero.

In some embodiments, each of the states S1 through S3 of the RF signal224A or the RF signal 224B has a one-third duty cycle. In severalembodiments, each of the states S1 through S3 of an RF signal, such asthe RF signal 224A or the RF signal 224B, has a different duty cyclethan a duty cycle of any of remaining of the states S1 through S3 of theRF signal. For example, the state S1 has of the RF signal an a% dutycycle, the state S2 of the RF signal has a duty cycle of b%, and thestate S3 of the RF signal as a duty cycle of (100-a-b)%, where a is adifferent integer than b.

It should be noted that the RF generator RFGa is controlled to operateat the frequency level f2x during the state S2. The power parameter ofthe RF signal generated by the RF generator RFGa during the state S2 isadded to the power parameter of the RF signal generated by the RFgenerator RFGb during the state S3. The plasma sheath 223 of plasmaformed within the plasma chamber 108 acts as the capacitor, whichcharges during the state S2 from the power parameter level P2xassociated with the frequency level f2x and discharges during the stateS3. The addition of the power parameters and the discharging of thecapacitor increases ion energy of ions of plasma within the plasmachamber 108 during the state S3 and decreases an angular spread of theion energy during the state S3. For example, a vertical directionalityof plasma within the plasma chamber 108 increases during the state S3with the addition of the power parameters during the state S3.

It should be noted that the power parameter levels P2x, P2y, and P3y arenon-zero as illustrated in the graph 222. Moreover, the frequency levelsf2x, f2y, and f3y are non-zero as illustrated in the graph 222.

FIG. 2E is a diagram of embodiments of the graphs 210, 212, and a graph230 to illustrate the states S1, S2, and S2 of the RF signal, such as anRF signal 232A, generated and supplied by the RF generator RFGa and ofthe RF signal, such as an RF signal 232B, generated and supplied by theRF generator RFGb. The states S1 through S3 of the RF signals 232A and232B repeat in synchronization with each cycle of the clock signal 204.The RF signal 232A has a frequency level f1x during the state S1, has afrequency level f2x during the state S2, and has a frequency level f3xduring the state S3. The frequency level f2x is lower than the frequencylevel f1x and the frequency level f3x is lower than the frequency levelf2x. Moreover, the RF signal 224B has a frequency level f1y during thestate S1, has a frequency level f2y during the state S2, and has afrequency level f3y during the state S3. The frequency level f2y isgreater than the frequency level f1y and the frequency level f3y isgreater than the frequency level f2y.

FIG. 3 is a diagram of embodiments of multiple graphs 302A and 302B toillustrate that with pulsing of frequency level of the RF signalgenerated by a frequency pulsed RF generator, such as the RF generatorRFGx or the RF generator RFGa, there is an increase in peak energy ofplasma ions that are incident on a surface of the substrate 122, such asa surface of a channel of the substrate 122. Each graph 302 a and 302 bplots an IEAD, which is a plot of an energy, measured in electron volts(eV), of plasma ions versus an angle theta measured in degrees acrossthe channel formed within the substrate 122. The graph 302 a plots theenergy when a frequency level of an RF generator is not pulsed, e.g.,operates in a continuous wave (CW) mode. The graph 302 b plots theenergy when the frequency pulsed RF generator is used. It should benoted that when a frequency level of the RF generator RFGx or RFGa ispulsed between multiple states, there is an increase in peak ion energyof plasma ions of plasma within the plasma chamber 108 compared to peakion energy of the plasma ions when the CW mode RF generator is used.Moreover, when a frequency level of the RF generator RFGx or RFGa ispulsed between multiple states, there is a decrease in angular spread ofthe plasma ions across the channel compared to an angular spread of theplasma ions when the CW mode RF generator is used. It should further benoted that as illustrated in the graphs 302 a and 302 b, an amount ofbias voltage that is supplied by the bias RF generator system 114 is thesame, such as 300 volts, independent of whether the frequency pulsed RFgenerator or the CW mode RF generator is used. The increase in the peakion energy and the decrease in the angular spread increases an etch rateof etching the substrate 122 and the bias voltage need not be increasedto increase the etch rate. For example, the bias voltage of the one ormore RF signals that are generated and supplied by the bias RF generatorsystem 114 is constant when a frequency level of the RF generator RFGxor RFGa is pulsed. As another example, the bias voltage of the one ormore RF signals that are generated and supplied by the bias RF generatorsystem 114 is substantially constant, e.g., is within a pre-determinedthreshold, is within 5-10% of a pre-determined value, when a frequencylevel of the RF generator RFGx or RFGa is pulsed.

FIG. 4 is a diagram of an embodiment of a graph 400 to illustrate thatwith an increase in the bias voltage that is supplied by the bias RFgenerator system 114, there is a decrease in the angular distribution ofplasma ions. The graph 400 plots the angular distribution, measured indegrees, versus the bias voltage. As evident, when the bias voltageincreases from 200 volts to 1600 volts, there is a decrease in theangular spread distribution and an increase in an etch rate. The angulardistribution is sometimes referred to herein as an angular spread.

During etching, the bias voltage is increased for a faster etch rate.Since peak ion energy increases and the angular spread of plasma ionsdecreases with an increase in the bias voltage, the increased biasvoltage etches a high aspect ratio feature in the substrate 122 fasterwhile maintaining a near vertical profile, such as a decent criticaldimension. However, the increased bias voltage narrows the angularspread, which increases an erosion of a mask layer, which is a top partof the substrate 122. Moreover, the increase in the bias voltage createsa complication in hardware implementation. Furthermore, beyond apre-determined amount of bias voltage, such as greater than 5 kilovolts,the angular spread does not become tighter due to a high thickness ofthe plasma sheath 123.

It should be noted that in one embodiment, an amount of bias voltagethat is supplied by the RF generator system 114 is less than 5kilovolts.

FIG. 5 is a diagram of an embodiment of a graph 500 to illustrate thatan angular spread that is comparable to that achieved with the increasein the bias voltage is achieved by pulsing one or more frequency levelsof the RF generator RFGx or RFGy or RFGa or RFGb or a combinationthereof. For the same bias voltage, when one or more frequency levels ofthe RF generator RF generator RFGx or RFGy or RFGa or RFGb or acombination thereof coupled to the upper electrode 106 is pulsed, thereis a decrease in the angular spread compared to when an RF generatoroperates in the CW mode. The decrease in the angular spread increases anetch rate of etching the substrate 122. There is no need to increase thebias voltage when one or more frequency levels of the RF generator RFGxor RFGy or RFGa or RFGb or a combination thereof is pulsed.

FIG. 6 is a diagram of embodiments of a graph 602A and a graph 602B toillustrate a difference in a critical dimension (CD) of a channel formedwithin the substrate 122. The graph 602A plots a height of a channel innanometers (nm) compared to a width of the channel in nanometers. Thecritical dimension of the channel is shown as 22.2 nm in the graph 602A.The critical dimension of the graph 602A is achieved when the CW mode RFgenerator is used instead of the RFGx or RFGy or RFGa or RFGb or acombination thereof. The graph 602B plots a height of the channel of thesubstrate 122 in nanometers compared to a width of the channel of thesubstrate 122 in nanometers. The critical dimension is shown as 20.1 nmin the graph 602B. The lower critical dimension in the graph 602Bcompared to that in the graph 602A is achieved when one or morefrequency levels of the RFGx or RFGy or RFGa or RFGb or a combinationthereof is pulsed. The low critical dimension is achieved when avertical directionality of plasma ions of plasma within the plasmachamber 108 is increased due to a decrease in the angular spread of theplasma ions. The plasma ions focus more on a bottom surface of thechannel of the substrate 122 when the vertical directionality isincreased to increase the etch rate.

FIG. 7A is a block diagram of an embodiment of a plasma tool 700 forachieving peak ion energy enhancement with a low angular spread. Theplasma tool 700 includes an RF generator RFGx1, the host computer 116,the IMN 104, the plasma chamber 108, the IMN 112, and the bias RFgenerator system 114. Examples of the RF generator RFGx1 include a lowfrequency RF generator, such as a 400 kHz RF generator, or a 2 MHz RFgenerator, or a 13.56 MHz RF generator. Other examples of the RFgenerator RFGx1 include a high frequency generator, such as a 13.56 MHzRF generator, or a 27 MHz RF generator, or a 60 MHz RF generator.

The RF generator RFGx1 includes the digital signal processor DSPx, thepower parameter controller PWRS1x, another power parameter controllerPWRS2x, an auto frequency tuner AFTx1, the RF power supply Psx, and thedriver system 118.

The DSPx is coupled to the power parameter controllers PWRS1x andPWRS2x, and to the auto-frequency tuner AFTx1. Moreover, the powerparameter controllers PWRS1x and PWR2x and the AFTx1 are coupled to thedriver system 118. The RF power supply Psx is coupled via an output ofthe RF generator RFGx1 to the RF cable 124.

The processor 132 accesses a recipe from the memory device 134. Examplesof the recipe include a power parameter set point to be applied to theRF generator RFGx1 for the state S1, a power parameter set point to beapplied to the RF generator RFGx1 for the state S2, a frequency setpoint to be applied to the RF generator RFGx1 for the states S1 and S2,a chemistry of the one or more process gases, or a combination thereof.

The processor 132 sends an instruction with the pulsed signal 102 to theDSPx of the RF generator RFGx1 via the cable 136. The instruction sentto the DSPx of the RF generator RFGx1 via the cable 136 has informationregarding the pulsed signal 102, the power parameter set point to beapplied to the RF generator RFGx1 for the state S1, the power parameterset point to be applied to the RF generator RFGx1 for the state S2, andthe frequency set point to be applied to the RF generator RFGx1 for thestates S1 and S2. The information regarding the pulsed signal 102indicates to the DSPx of the RF generator RFGx1 that the RF signal to begenerated by the RF generator RFGx1 is to transition from the state S1to the state S2 at the transition time tst1 of the pulsed signal 102 andthat the RF signal is to transition from the state S2 to the state S1 atthe transition time tst2 of the pulsed signal 102. The DSPx of the RFgenerator RFGx1 determines from the instruction that the power parameterset point for the state S1 is to be applied during the state S1 of thepulsed signal 102, the power parameter set point for the state S2 is tobe applied during the state S2 of the pulsed signal 102, and thefrequency set point for the states S1 and S2 is to be applied during thestates S1 and S2 of the pulsed signal 102. Moreover, the DSPx of the RFgenerator RFGx1 determines from the instruction and the pulsed signal102, that the RF signal to be generated by the RF generator RFGx1 is totransition from the state S1 to the state S2 at the transition time tst1of the pulsed signal 102 and that the RF signal is to transition fromthe state S2 to the state S1 at the transition time tst2 of the pulsedsignal 102.

At the transition time tst2 of the cycle of the pulsed signal 102, theDSPx of the RF generator RFGx1 sends the power parameter set point forthe state S1 to the power parameter controller PWRS1x. Similarly, at thetransition time tst1 of the cycle of the pulsed signal 102, the DSPxsends the power parameter set point for the state S2 to the powerparameter controller PWRS2x. Moreover, at the transition time tst2 ortst1 of the cycle of the pulsed signal 102, the DSPx sends the frequencyset point for the states S1 and S2 to the auto-frequency tuner AFTx1.

Upon receiving the power parameter set point for the state S1, the powerparameter controller PWRS1x of the RF generator RFGx1 determines anamount of current corresponding to the power parameter set point for thestate S1. Based on the amount of current that is to be generated by thedriver system 118 of the RF generator RFGx1 during the state S1, thepower parameter controller PWRS1x of the RF generator RFGx1 generates acommand signal and sends the command signal to the driver system 118.For the state S1, in response to receiving the command signal, thedriver system 118 of the RF generator RFGx1 generates and sends acurrent signal having the amount of current to the RF power supply Psx.The RF power supply Psx of the RF generator RFGx1, upon receiving thecurrent signal generates the RF signal having the power parameter setpoint for the state S1 and supplies the RF signal via the output of theRF generator RFGx1 and the RF cable 124 to the input of the IMN 104. Thepower parameter set point for the state S1 is maintained during thestate S1 by the RF power supply Psx of the RF generator RFGx1.

Similarly, upon receiving the power parameter set point for the stateS2, the power parameter controller PWRS2x of the RF generator RFGx1determines an amount of current corresponding to the power parameter setpoint for the state S2. Based on the amount of current that is to begenerated by the driver system 118 of the RF generator RFGx1 during thestate S2, the power parameter controller PWRS2x of the RF generatorRFGx1 generates a command signal and sends the command signal to thedriver system 118. For the state S2, in response to receiving thecommand signal, the driver system 118 of the RF generator RFGx1generates and sends a current signal having the amount of current to theRF power supply Psx. The RF power supply Psx of the RF generator RFGx1,upon receiving the current signal generates the RF signal having thepower parameter set point for the state S2 and supplies the RF signalvia the output of the RF generator RFGx1 and the RF cable 124 to theinput of the IMN 104. The power parameter set point for the state S2 ismaintained during the state S2 by the RF power supply Psx of the RFgenerator RFGx1.

Moreover, upon receiving the frequency set point for the states S1 andS2, the auto-frequency tuner AFTx1 of the RF generator RFGx1 determinesan amount of current corresponding to the frequency set point for thestate S1. Based on the amount of current that is to be generated by thedriver system 118 during the states S1 and S2, the auto-frequency tunerAFTx1 generates a command signal and sends the command signal to thedriver system 118 of the RF generator RFGx1. For the states S1 and S2,in response to receiving the command signal, the driver system 118 ofthe RF generator RFGx1 generates and sends a current signal having theamount of current to the RF power supply Psx of the RF generator RFGx1.The RF power supply Psx of the RF generator RFGx1, upon receiving thecurrent signal generates the RF signal having the frequency set pointfor the state S1 and supplies the RF signal via the output of the RFgenerator RFGx1 and the RF cable 124 to the input of the IMN 104. Thefrequency set point for the states S1 and S2 is maintained during thestates S1 and S2 by the RF power supply Psx of the RF generator RFGx1.The RF signal having the power parameter set point for the state S1 andthe frequency set point for the state S1 is the RF signal generated bythe RF generator RFGx1 during the state S1. Similarly, the RF signalhaving the power parameter set point for the state S2 and the frequencyset point for the state S2 is the RF signal generated by the RFgenerator RFGx1 during the state S2.

The input of the IMN 104 receives the RF signal generated by the RFpower supply Psx of the RF generator RFGx1 via the RF cable 124 from theoutput of the RF generator RFGx1, and matches an impedance of the loadcoupled to the output of the IMN 104 with an impedance of a sourcecoupled to the input of the IMN 104 to generate a modified RF signal atthe output of the IMN 104. An example of the source coupled to the inputof the IMN 104 includes the RF cable 124 and the RF generator RFGx1. Themodified RF signal is sent via the RF transmission cable 126 to theupper electrode 106, such as to the end E1 of the TCP coil.

When the one or more process gases are supplied between the upperelectrode 106 and the chuck 110, the modified RF signal is supplied tothe upper electrode 106, and the output RF signal is supplied to thechuck 110, the one or more process gases are ignited to generate ormaintain plasma within the plasma chamber 108.

In various embodiments, the power parameter controllers PWRS1x andPWRS2x, and the auto-frequency tuner AFTx1 are modules, e.g., portions,etc., of a computer program that is executed by the DSPx of the RFgenerator RFGx1.

In several embodiments, the power parameter controllers PWRS1x andPWRS2x, and the auto-frequency tuner AFTx1 are separate integratedcircuits that are coupled to an integrated circuit of the DSPx of the RFgenerator RFGx1. For example, the power parameter controller PWRS1x is afirst integrated circuit of the RF generator RFGx1, the power parametercontroller PWRS2x is a second integrated circuit of the RF generatorRFGx1, the auto-frequency tuner AFTx1 is a third integrated circuit ofthe RF generator RFGx1, and the DSPx is a fourth integrated circuit ofthe RF generator RFGx1. Each of the first through third integratedcircuit of the RF generator RFGx1 is coupled to the fourth integratedcircuit of the RF generator RFGx1.

In various embodiments, two RF generators are coupled to the IMN 104.For example, the RF generator RFGy is coupled to the IMN 104 via the RFcable 130 to the other input of the IMN 104. The IMN 104 combines the RFsignals received from the RF generator RFGx1 and the RF generator RFGy,and matches an impedance of the load coupled to the output of the IMN104 with that of the source, e.g., the RF generator RFGx1, the RFgenerator RFGy, the RF cable 124, and the RF cable 130, etc., togenerate the modified RF signal at the output of the IMN 104.

FIG. 7B is a diagram of embodiments of the graph 140, a graph 710, and agraph 712 to illustrate pulsing of a power parameter of the RF signalgenerated by the RF generator RFGx1 of FIG. 7A. The graph 710 plots apower parameter level of the RF signal, such as an RF signal 714, thatis generated by the RF generator RFGx1 versus the time t. Similarly, thegraph 712 plots a power parameter level of the RF signal, such as an RFsignal 716, that is generated by the RF generator RFGx1 versus the timet.

With reference to graphs 140 and 710, during the state S1, the RF signal714 has a power parameter level of Px1 and a frequency level of fx1.Furthermore, at the transition time tst1, the RF signal 714 transitionsfrom the state S1 to the state S2. During the state S2, the RF signal714 has a power parameter level of zero and a frequency level of zero.At the transition time tst2, the RF signal 714 transitions from thestate S2 back to the state S1.

It should be noted that a duty cycle of the state S1 of the RF signal714 is the same as a duty cycle of the state S2 of the RF signal 714.For example, the duty cycle of the state S1 is 50% and the duty cycle ofthe state S2 is 50%. The state S1 of the RF signal 714 occupies 50% ofthe cycle of the pulsed signal 102 and the state S2 of the RF signal 714occupies the remaining 50% of the cycle of the pulsed signal 102.

In various embodiments, a duty cycle of the state S1 of the RF signal714 is different from a duty cycle of the state S2 of the RF signal 714.For example, the duty cycle of the state S1 is 25% and the duty cycle ofthe state S2 is 75%. The state S1 of the RF signal 714 occupies 25% ofthe cycle of the pulsed signal 102 and the state S2 of the RF signal 714occupies the remaining 75% of the cycle of the pulsed signal 102. Asanother example, the duty cycle of the state S1 is a% and the duty cycleof the state S2 is (100-a)%. The state S1 of the RF signal 714 occupiesa% of the cycle of the pulsed signal 102 and the state S2 of the RFsignal 714 occupies the remaining (100-a)% of the cycle of the pulsedsignal 102.

It should be noted that the power parameter level Px1 and the frequencylevel fx1 are non-zero as illustrated in the graph 710.

The graph 712 is similar to the graph 710 except that the RF signals 714and 716 have difference power parameter levels during the state S2. Forexample, the RF signal 714 has the power parameter level of zero duringthe state S2 and the RF signal 716 has a power parameter level of Px2during the state S2. Moreover, the RF signal 716 has a frequency levelof fx2 during the state S2 and the frequency level fx2 during the stateS2 is the same as the frequency level fx1 of the RF signal 716 duringthe state S1. The RF signal 716 has the power parameter level Px1 duringthe state S1.

With reference to graphs 140 and 712, the state S1 of the RF signal 716is the same as the state S1 of the RF signal 714. For example, the powerparameter level Px1 of the RF signal 716 is the same as that of thepower parameter level Px1 of the RF signal 714 during the state S1.Also, the frequency level fx1 of the RF signal 716 is the same as thatof the frequency level fx1 of the RF signal 714 during the state S1.

Furthermore, at the transition time tst1, the RF signal 716 transitionsfrom the state S1 to the state S2. During the state S2, the powerparameter level Px2 of the RF signal 716 is greater than the powerparameter level Px1 of zero of the RF signal 714 during the state S1 butlower than the power parameter level Px1 of the RF signal 716 during thestate S1. At the transition time tst2, the RF signal 716 transitionsfrom the state S2 back to the state S1.

It should be noted that the power parameters level Px1 and Px2 and thefrequency levels fx1 and fx2 are non-zero as illustrated in the graph712.

It should be noted that a duty cycle of the state S1 of the RF signal716 is the same as a duty cycle of the state S2 of the RF signal 716.For example, the duty cycle of the state S1 of the RF signal 716 is 50%and the duty cycle of the state S2 of the RF signal 716 is 50%. Thestate S1 of the RF signal 716 occupies 50% of the cycle of the pulsedsignal 102 and the state S2 of the RF signal 716 occupies the remaining50% of the cycle of the pulsed signal 102.

In various embodiments, a duty cycle of the state S1 of the RF signal716 is different from a duty cycle of the state S2 of the RF signal 716.For example, the duty cycle of the state S1 of the RF signal 716 is 25%and the duty cycle of the state S2 of the RF signal 716 is 75%. Thestate S1 of the RF signal 716 occupies 25% of the cycle of the pulsedsignal 102 and the state S2 of the RF signal 716 occupies the remaining75% of the cycle of the pulsed signal 102. As another example, the dutycycle of the state S1 of the RF signal 716 is a% and the duty cycle ofthe state S2 of the RF signal 716 is (100-a)%. The state S1 of the RFsignal 716 occupies a% of the cycle of the pulsed signal 102 and thestate S2 of the RF signal 716 occupies the remaining (100-a)% of thecycle of the pulsed signal 102.

It should be noted that the RF generator RFGx1 is controlled to operateat the power parameter level Px2 during the state S2. The powerparameter of the RF signal generated by the RF generator RFGx1 duringthe state S2 is added to the power parameter of the RF signal generatedby the RF generator RFGx1 during the state S1. The plasma sheath 123 ofplasma formed within the plasma chamber 108 acts as the capacitor, whichcharges during the state S2 from the power parameter level Px2associated with the frequency level fx2 and discharges during the stateS1. The addition of the power parameters and the discharging of thecapacitor increases ion energy of ions of plasma within the plasmachamber 108 during the state S1 and decreases an angular spread of theion energy during the state S1. For example, a vertical directionalityof plasma within the plasma chamber 108 increases during the state S1with the addition of the power parameters during the state S1.

FIG. 8 is a diagram of embodiments of multiple graphs 800, 802, 804, and806 to illustrate that with an increase in the bias voltage, there is anincrease in vertical directionality of plasma ions. Each graph 800, 802,804, and 806 plots an energy of plasma ions versus an angle measuredacross the channel formed within the substrate 122. As shown, with anincrease in the bias voltage that is supplied by the bias RF generatorsystem 114, there is an increase in peak ion energy of plasma within theplasma chamber 108. With the increase in the peak ion energy, there is adecrease in the angular spread of plasma ions across the channel andincrease in the vertical directionality of the plasma ions.

FIG. 9 is a diagram of embodiments of multiple graphs 902 and 904 toillustrate that with pulsing of a power parameter level of an RF signalgenerated by a power parameter pulsed RF generator, such as the RFgenerator RFGx or RFGy or RFGa or RFGb or RFGx1, there is an increase inpeak energy of plasma ions that are incident on the surface of thesubstrate 122. Each graph 902 and 904 plots an ion energy distributionfunction (IEDF), which is a plot of an energy of plasma ions versus anangle measured across a channel formed within the substrate 122. Thegraph 902 plots the energy when a power parameter level of an RFgenerator is not pulsed, e.g., operates in the CW mode. The graph 904plots the energy when the power parameter pulsed RF generator is used topulse a power parameter level between multiple states. It should benoted that when a power parameter level of the power parameter pulsed RFgenerator is pulsed between multiple states, there is an increase inpeak ion energy of plasma ions of plasma within the plasma chamber 108compared to peak ion energy of the plasma ions when the CW mode RFgenerator is used. Moreover, when a power parameter level of the powerparameter pulsed RF generator is pulsed between multiple states, thereis a decrease in angular distribution of the plasma ions across thechannel compared to an angular distribution of the plasma ions when theCW mode RF generator is used. It should further be noted that an amountof bias voltage that is supplied by the bias RF generator system 114 isthe same, such as 300 volts, independent of whether the power parameterpulsed RF generator or the CW mode RF generator is used. The increase inthe peak ion energy and the decrease in the angular distributionincreases an etch rate of etching the substrate 122 and the bias voltageneed not be increased to increase the etch rate. For example, the biasvoltage of the one or more RF signals that are generated and supplied bythe bias RF generator system 114 is constant when a power parameterlevel of the power parameter pulsed RF generator is pulsed.

FIG. 10 is a diagram of an embodiment of the graph 400.

FIG. 11 is a diagram of an embodiment of a graph 1100 to illustrate thatan angular spread that is comparable to that achieved with the increasein the bias voltage is achieved by pulsing a power parameter level ofthe power parameter pulsed RF generator. For the same bias voltage, whena power parameter level of an RF generator coupled to the upperelectrode 106 is operated in the CW mode, e.g., is not pulsed, theangular spread is higher. The angular spread is higher compared to thatachieved using the power parameter pulsed RF generator. There is no needto increase the bias voltage when a power parameter level of the powerparameter pulsed RF generator is pulsed to achieve the lower angularspread to increase the etch rate.

FIG. 12 is a diagram of embodiments of a graph 1202A and a graph 1202Bto illustrate a difference in a critical dimension of the channel formedwithin the substrate 122. The graph 1202A plots a height of a channel innanometers compared to a width of the channel in nanometers. Thecritical dimension of the channel is shown as 21.9 nm in the graph1202A. The critical dimension of the graph 1202A is achieved when the CWmode RF generator is used instead of the power parameter pulsed RFgenerator. The graph 1202B plots a height of the channel of thesubstrate 122 in nanometers compared to a width of the channel of thesubstrate 122 in nanometers. The critical dimension is shown as 19.2 nmin the graph 1202B. The lower critical dimension in the graph 1202Bcompared to that in the graph 1202A is achieved when a power parameterlevel of the power parameter pulsed RF generator is pulsed. The lowcritical dimension is achieved when a vertical directionality of theplasma ions of plasma within the plasma chamber 108 is increased due toa decrease in the angular spread of the plasma ions of plasma within theplasma chamber 108.

FIG. 13A is a block diagram of an embodiment of a plasma tool 1300 forachieving peak ion energy enhancement with a low angular spread. Theplasma tool 1300 is the same as the plasma tool 100 of FIG. 1A exceptthat in the plasma tool 1300, a bias RF generator RFGbs is used insteadof the bias RF generator system 114. The bias RF generator RFGbs is amulti-state RF generator compared to the bias RF generator system 114,which is a continuous wave mode RF generator. The plasma tool 1300further includes the host computer 116, the IMN 112, the plasma chamber108, the RF generator RFGx (shown in FIG. 1A), the RF generator RFGy(shown in FIG. 1A), and the IMN 104 (shown in FIG. 1A).

The RF generator RFGbs includes a digital signal processor DSPbs, apower parameter controller PWRS1, another power parameter controllerPWRS2, an auto frequency tuner AFTS, an RF power supply Pbs, and adriver system 1302. The digital signal processor DSPbs is coupled to thepower parameter controllers PWRS1 and PWRS2, and to the auto-frequencytuner AFTS. Moreover, the power parameter controllers PWRS1 and PWRS2and the auto-frequency tuner AFTS are coupled to the driver system 1302.The driver system 1302 is coupled to the RF power supply Pbs. The RFpower supply Pbs is coupled via an output of the RF generator RFGbs tothe RF cable system 137, such as to an RF cable of the RF cable system137.

The processor 132 accesses a recipe from the memory device 134. Examplesof the recipe include a power parameter set point to be applied to theRF generator RFGbs for the state S1, a power parameter set point to beapplied to the RF generator RFGbs for the state S2, a frequency setpoint to be applied to the RF generator RFGx for the states S1 and S2,or a combination thereof.

The processor 132 sends an instruction with the pulsed signal 102 to theDSPbs via the cable 117. The instruction sent to the DSPbs via the cable117 has information regarding the pulsed signal 102, the power parameterset point to be applied to the RF generator RFGbs for the state S1, thepower parameter set point to be applied to the RF generator RFGbs forthe state S2, and the frequency set point to be applied to the RFgenerator RFGbs for the states S1 and S2. The information regarding thepulsed signal 102 indicates to the DSPbs that the RF signal to begenerated by the RF generator RFGbs is to transition from the state S1to the state S2 at the transition time tst1 of the pulsed signal 102 andthat the RF signal is to transition from the state S2 to the state S1 atthe transition time tst2 of the pulsed signal 102. The DSPbs determinesfrom the instruction that the power parameter set point for the state S1is to be applied during the state S1 of the pulsed signal 102, the powerparameter set point for the state S2 is to be applied during the stateS2 of the pulsed signal 102, and the frequency set point for the statesS1 and S2 is to be applied during the states S1 and S2 of the pulsedsignal 102. Moreover, the DSPbs determines from the instruction and thepulsed signal 102, that the RF signal to be generated by the RFgenerator RFGbs is to transition from the state S1 to the state S2 atthe transition time tst1 of the pulsed signal 102 and that the RF signalis to transition from the state S2 to the state S1 at the transitiontime tst2 of the pulsed signal 102. The transition times tst1 and tst2repeat for each cycle of the pulsed signal 102.

At the transition time tst2 of the cycle of the pulsed signal 102, theDSPbs sends the power parameter set point for the state S1 to the powerparameter controller PWRS1. Similarly, at the transition time tst1 ofthe cycle of the pulsed signal 102, the DSPbs sends the power parameterset point for the state S2 to the power parameter controller PWRS2.Moreover, at the transition time tst2 or tst1 of the cycle of the pulsedsignal 102, the DSPbs sends the frequency set point for the states S1and S2 to the auto-frequency tuner AFTS.

Upon receiving the power parameter set point for the state S1, the powerparameter controller PWRS1 determines an amount of current correspondingto the power parameter set point for the state S1. Based on the amountof current that is to be generated by the driver system 1302 during thestate S1, the power parameter controller PWRS1 generates a commandsignal and sends the command signal to the driver system 1302. For thestate S1, in response to receiving the command signal, the driver system1302 generates and sends a current signal having the amount of currentto the RF power supply Pbs. The RF power supply Pbs, upon receiving thecurrent signal generates the RF signal having the power parameter setpoint for the state S1 and supplies the RF signal via the output of theRF generator RFGbs and the RF cable of the RF cable system 137 to theinput of the IMN 112. The power parameter set point for the state S1 ismaintained during the state S1 by the RF power supply Pbs of the RFgenerator RFGbs.

Similarly, upon receiving the power parameter set point for the stateS2, the power parameter controller PWRS2 determines an amount of currentcorresponding to the power parameter set point for the state S2. Basedon the amount of current that is to be generated by the driver system1302 during the state S2, the power parameter controller PWRS2 generatesa command signal and sends the command signal to the driver system 1302.For the state S2, in response to receiving the command signal, thedriver system 1302 generates and sends a current signal having theamount of current to the RF power supply Psbs. The RF power supply Pbs,upon receiving the current signal generates the RF signal having thepower parameter set point for the state S2 and supplies the RF signalvia the output of the RF generator RFGbs and the RF cable of the RFcable system 137 to the input of the IMN 112. The power parameter setpoint for the state S2 is maintained during the state S2 by the RF powersupply Pbs of the RF generator RFGbs.

Moreover, upon receiving the frequency set point for the states S1 andS2, the auto-frequency tuner AFTS determines an amount of currentcorresponding to the frequency set point for the states S1 and S2. Basedon the amount of current that is to be generated by the driver system1302 during the states S1 and S2, the auto-frequency tuner AFTSgenerates a command signal and sends the command signal to the driversystem 1302. For the states S1 and S2, in response to receiving thecommand signal, the driver system 1302 generates and sends a currentsignal having the amount of current to the RF power supply Pbs. The RFpower supply Pbs, upon receiving the current signal generates the RFsignal having the frequency set point for the states S1 and S2 andsupplies the RF signal via the output of the RF generator RFGbs and theRF cable of the RF cable system 137 to the input of the IMN 112. Thefrequency set point for the states S1 and S2 is maintained during thestates S1 and S2 by the RF power supply Pbs. The RF signal having thepower parameter set point for the state S1 and the frequency set pointfor the states S1 and S2 is the RF signal generated by the RF generatorRFGbs during the state S1. Similarly, the RF signal having the powerparameter set point for the state S2 and the frequency set point for thestates S1 and S2 is the RF signal generated by the RF generator RFGbsduring the state Ss.

The input of the IMN 112 receives the RF signal generated by the RFpower supply Pbs via the RF cable of the RF cable system 137 from theoutput of the RF generator RFGbs, and matches an impedance of the loadcoupled to the output of the IMN 112 with an impedance of a sourcecoupled to the input of the IMN 112 to generate an output RF signal atthe output of the IMN 112. An example of the source coupled to the inputof the IMN 112 includes the RF cable system 137 and the RF generatorRFGbs. The output RF signal is sent via the RF transmission line 139 tothe chuck 110, such as to the lower electrode of the chuck 110.

When the one or more process gases are supplied between the upperelectrode 106 and the chuck 110, the modified RF signal is supplied tothe upper electrode 106, and the output RF signal is supplied to thechuck 110, the one or more process gases are ignited to generate ormaintain plasma within the plasma chamber 108.

In various embodiments, the power parameter controllers PWRS1 and PWRS2,and the auto-frequency tuner AFTS are modules, e.g., portions, etc., ofa computer program that is executed by the DSPbs.

In several embodiments, the power parameter controllers PWRS1 and PWRS2,and the auto-frequency tuner AFTS are separate integrated circuits thatare coupled to an integrated circuit of the DSPbs. For example, thepower parameter controller PWRS1 is a first integrated circuit of the RFgenerator RFGbs, the power parameter controller PWRS2 is a secondintegrated circuit of the RF generator RFGbs, the auto-frequency tunerAFTS is a third integrated circuit of the RF generator RFGbs, and theDSPbs is a fourth integrated circuit of the RF generator RFGbs. Each ofthe first through third integrated circuit of the RF generator RFGbs iscoupled to the fourth integrated circuit of the RF generator RFGbs.

FIG. 13B is a diagram of embodiments of the graph 140, a graph 1310, anda graph 1312 to illustrate pulsing of a power parameter of the RF signalgenerated by the RF generator RFGbs of FIG. 13A. The graph 1310 plots apower parameter level of the RF signal, such as an RF signal 1314, thatis generated by the RF generator RFGbs versus the time t. Similarly, thegraph 1312 plots a power parameter level of the RF signal, such as an RFsignal 1316, that is generated by the RF generator RFGbs versus the timet.

With reference to graphs 140 and 1310, during the state S1, the RFsignal 1314 has a power parameter level of zero and a frequency level ofzero. Furthermore, at the transition time tst1, the RF signal 1314transitions from the state S1 to the state S2. During the state S2, theRF signal 1314 has a power parameter level of Pb2 and a frequency levelof fb2. At the transition time tst2, the RF signal 1314 transitions fromthe state S2 back to the state S1. The zero power parameter level of theRF signal 1314 avoids plasma ions generated during the state S1 frombeing directed towards the chuck 110. As such, the plasma ions arepreserved for application during the state S2 to increase verticaldirectionality of the plasma ions to further increase the etch rate.

It should be noted that a duty cycle of the state S1 of the RF signal1314 is the same as a duty cycle of the state S2 of the RF signal 1314.For example, the duty cycle of the state S1 is 50% and the duty cycle ofthe state S2 is 50%. The state S1 of the RF signal 1314 occupies 50% ofthe cycle of the pulsed signal 102 and the state S2 of the RF signal1314 occupies the remaining 50% of the cycle of the pulsed signal 102.

In various embodiments, a duty cycle of the state S1 of the RF signal1314 is different from a duty cycle of the state S2 of the RF signal1314. For example, the duty cycle of the state S1 is 25% and the dutycycle of the state S2 is 75%. The state S1 of the RF signal 1314occupies 25% of the cycle of the pulsed signal 102 and the state S2 ofthe RF signal 1314 occupies the remaining 75% of the cycle of the pulsedsignal 102. As another example, the duty cycle of the state S1 is a% andthe duty cycle of the state S2 is (100-a)%. The state S1 of the RFsignal 1314 occupies a% of the cycle of the pulsed signal 102 and thestate S2 of the RF signal 1314 occupies the remaining (100-a)% of thecycle of the pulsed signal 102.

It should be noted that the power parameter level Pb2 and the frequencylevel fb2 are non-zero as illustrated in the graph 1310.

The graph 1312 is similar to the graph 1310 except that the RF signals1314 and 1316 have difference power parameter levels during the stateS1. For example, the RF signal 1314 has the power parameter level ofzero during the state S1 and the RF signal 1316 has a power parameterlevel of Pb1 during the state S1. Moreover, the RF signal 1316 has afrequency level of fb1 during the state S1 and the frequency level fb1during the state S1 is the same as the frequency level fb2 of the RFsignal 1316 during the state S2. The RF signal 1316 has the powerparameter level Pb2 during the state S2. The lower power parameter levelof the RF signal 1316 during the state S1 compared to that during thestate S2 avoids plasma ions generated during the state S1 from beingdirected towards the chuck 110 during the state S1. As such, the plasmaions are preserved for application during the state S2 to increasevertical directionality of the plasma ions to further increase the etchrate.

With reference to graphs 140 and 1312, the state S2 of the RF signal1316 is the same as the state S2 of the RF signal 1314. For example,during the state S2, the RF signal 1316 has the power parameter level ofPb2, which is the same as that of the power parameter level Pb2 of theRF signal 1314 during the state S2. Also, during the state S2, the RFsignal 1316 has the frequency level of fb2, which is the same as that ofthe frequency level of the RF signal 1314 during the state S2.

Furthermore, at the transition time tst1, the RF signal 1316 transitionsfrom the state S1 to the state S2. The power parameter level of Pb1 isgreater than the power parameter level of zero of the RF signal 1314during the state S1 but lower than the power parameter level Pb2 of theRF signal 1316 during the state S2. At the transition time tst2, the RFsignal 1316 transitions from the state S2 back to the state S1.

It should be noted that the power parameters level Pb1 and Pb2 and thefrequency levels fb1 and fb2 are non-zero as illustrated in the graph1312.

It should be noted that a duty cycle of the state S1 of the RF signal1316 is the same as a duty cycle of the state S2 of the RF signal 1316.For example, the duty cycle of the state S1 of the RF signal 1316 is 50%and the duty cycle of the state S2 of the RF signal 1316 is 50%. Thestate S1 of the RF signal 1316 occupies 50% of the cycle of the pulsedsignal 102 and the state S2 of the RF signal 1316 occupies the remaining50% of the cycle of the pulsed signal 102.

In various embodiments, a duty cycle of the state S1 of the RF signal1316 is different from a duty cycle of the state S2 of the RF signal1316. For example, the duty cycle of the state S1 of the RF signal 1316is 25% and the duty cycle of the state S2 of the RF signal 1316 is 75%.The state S1 of the RF signal 1316 occupies 25% of the cycle of thepulsed signal 102 and the state S2 of the RF signal 1316 occupies theremaining 75% of the cycle of the pulsed signal 102. As another example,the duty cycle of the state S1 of the RF signal 1316 is a% and the dutycycle of the state S2 of the RF signal 1316 is (100-a)%. The state S1 ofthe RF signal 1316 occupies a% of the cycle of the pulsed signal 102 andthe state S2 of the RF signal 1316 occupies the remaining (100-a)% ofthe cycle of the pulsed signal 102.

In some embodiments, the frequency level fb1 is different from, such aslower than or higher than, the frequency level fb2.

Embodiments described herein may be practiced with various computersystem configurations including hand-held hardware units, microprocessorsystems, microprocessor-based or programmable consumer electronics,minicomputers, mainframe computers and the like. The embodiments canalso be practiced in distributed computing environments where tasks areperformed by remote processing hardware units that are linked through anetwork.

In some embodiments, a controller is part of a system, which may be partof the above-described examples. Such systems include semiconductorprocessing equipment, including a processing tool or tools, chamber orchambers, a platform or platforms for processing, and/or specificprocessing components (a wafer pedestal, a gas flow system, etc.). Thesesystems are integrated with electronics for controlling their operationbefore, during, and after processing of a semiconductor wafer orsubstrate. The electronics is referred to as the “controller,” which maycontrol various components or subparts of the system or systems. Thecontroller, depending on the processing requirements and/or the type ofsystem, is programmed to control any of the processes disclosed herein,including the delivery of process gases, temperature settings (e.g.,heating and/or cooling), pressure settings, vacuum settings, powersettings, RF generator settings, RF matching circuit settings, frequencysettings, flow rate settings, fluid delivery settings, positional andoperation settings, wafer transfers into and out of a tool and othertransfer tools and/or load locks coupled to or interfaced with a system.

Broadly speaking, in a variety of embodiments, the controller is definedas electronics having various integrated circuits, logic, memory, and/orsoftware that receive instructions, issue instructions, controloperation, enable cleaning operations, enable endpoint measurements, andthe like. The integrated circuits include chips in the form of firmwarethat store program instructions, digital signal processors (DSPs), chipsdefined as ASICs, PLDs, and/or one or more microprocessors, ormicrocontrollers that execute program instructions (e.g., software). Theprogram instructions are instructions communicated to the controller inthe form of various individual settings (or program files), defining theparameters, the factors, the variables, etc., for carrying out aparticular process on or for a semiconductor wafer or to a system. Theprogram instructions are, in some embodiments, a part of a recipedefined by process engineers to accomplish one or more processing stepsduring the fabrication of one or more layers, materials, metals, oxides,silicon, silicon dioxide, surfaces, circuits, and/or dies of a wafer.

The controller, in some embodiments, is a part of or coupled to acomputer that is integrated with, coupled to the system, otherwisenetworked to the system, or a combination thereof. For example, thecontroller is in a “cloud” or all or a part of a fab host computersystem, which allows for remote access of the wafer processing. Thecomputer enables remote access to the system to monitor current progressof fabrication operations, examines a history of past fabricationoperations, examines trends or performance metrics from a plurality offabrication operations, to change parameters of current processing, toset processing steps to follow a current processing, or to start a newprocess.

In some embodiments, a remote computer (e.g. a server) provides processrecipes to a system over a network, which includes a local network orthe Internet. The remote computer includes a user interface that enablesentry or programming of parameters and/or settings, which are thencommunicated to the system from the remote computer. In some examples,the controller receives instructions in the form of data, which specifythe parameters, factors, and/or variables for each of the processingsteps to be performed during one or more operations. It should beunderstood that the parameters, factors, and/or variables are specificto the type of process to be performed and the type of tool that thecontroller is configured to interface with or control. Thus as describedabove, the controller is distributed, such as by including one or morediscrete controllers that are networked together and working towards acommon purpose, such as the processes and controls described herein. Anexample of a distributed controller for such purposes includes one ormore integrated circuits on a chamber in communication with one or moreintegrated circuits located remotely (such as at the platform level oras part of a remote computer) that combine to control a process on thechamber.

Without limitation, in various embodiments, example systems to which themethods are applied include a plasma etch chamber or module, adeposition chamber or module, a spin-rinse chamber or module, a metalplating chamber or module, a clean chamber or module, a bevel edge etchchamber or module, a physical vapor deposition (PVD) chamber or module,a chemical vapor deposition (CVD) chamber or module, an atomic layerdeposition (ALD) chamber or module, an atomic layer etch (ALE) chamberor module, an ion implantation chamber or module, a track chamber ormodule, and any other semiconductor processing systems that isassociated or used in the fabrication and/or manufacturing ofsemiconductor wafers.

It is further noted that in some embodiments, the above-describedoperations apply to several types of plasma chambers, e.g., a plasmachamber including an inductively coupled plasma (ICP) reactor, atransformer coupled plasma chamber, conductor tools, dielectric tools, aplasma chamber including an electron cyclotron resonance (ECR) reactor,etc. For example, one or more RF generators are coupled to an inductorwithin the ICP reactor. Examples of a shape of the inductor include asolenoid, a dome-shaped coil, a flat-shaped coil, etc.

As noted above, depending on the process step or steps to be performedby the tool, the host computer communicates with one or more of othertool circuits or modules, other tool components, cluster tools, othertool interfaces, adjacent tools, neighboring tools, tools locatedthroughout a factory, a main computer, another controller, or tools usedin material transport that bring containers of wafers to and from toollocations and/or load ports in a semiconductor manufacturing factory.

With the above embodiments in mind, it should be understood that some ofthe embodiments employ various computer-implemented operations involvingdata stored in computer systems. These operations are those physicallymanipulating physical quantities. Any of the operations described hereinthat form part of the embodiments are useful machine operations.

Some of the embodiments also relate to a hardware unit or an apparatusfor performing these operations. The apparatus is specially constructedfor a special purpose computer. When defined as a special purposecomputer, the computer performs other processing, program execution orroutines that are not part of the special purpose, while still beingcapable of operating for the special purpose.

In some embodiments, the operations may be processed by a computerselectively activated or configured by one or more computer programsstored in a computer memory, cache, or obtained over the computernetwork. When data is obtained over the computer network, the data maybe processed by other computers on the computer network, e.g., a cloudof computing resources.

One or more embodiments can also be fabricated as computer-readable codeon a non-transitory computer-readable medium. The non-transitorycomputer-readable medium is any data storage hardware unit, e.g., amemory device, etc., that stores data, which is thereafter be read by acomputer system. Examples of the non-transitory computer-readable mediuminclude hard drives, network attached storage (NAS), ROM, RAM, compactdisc-ROMs (CD-ROMs), CD-recordables (CD-Rs), CD-rewritables (CD-RWs),magnetic tapes and other optical and non-optical data storage hardwareunits. In some embodiments, the non-transitory computer-readable mediumincludes a computer-readable tangible medium distributed over anetwork-coupled computer system so that the computer-readable code isstored and executed in a distributed fashion.

Although the method operations above were described in a specific order,it should be understood that in various embodiments, other housekeepingoperations are performed in between operations, or the method operationsare adjusted so that they occur at slightly different times, or aredistributed in a system which allows the occurrence of the methodoperations at various intervals, or are performed in a different orderthan that described above.

It should further be noted that in an embodiment, one or more featuresfrom any embodiment described above are combined with one or morefeatures of any other embodiment without departing from a scopedescribed in various embodiments described in the present disclosure.

Although the foregoing embodiments have been described in some detailfor purposes of clarity of understanding, it will be apparent thatcertain changes and modifications can be practiced within the scope ofappended claims. Accordingly, the present embodiments are to beconsidered as illustrative and not restrictive, and the embodiments arenot to be limited to the details given herein.

1. A controller comprising: a processor configured to: control a primaryradio frequency (RF) generator to output a primary RF signal that pulsesin a first manner between a primary frequency level during a first timeperiod and an off frequency level during a second time period; control asecondary RF generator to output a secondary RF signal that pulses in asecond manner between the off frequency level during the first timeperiod and a secondary frequency level during the second time period,wherein the primary and secondary RF generators are coupled to an upperelectrode of a plasma chamber via an impedance matching network; controlthe primary RF generator to output the primary RF signal that pulsesbetween the primary and off frequency levels during additional timeperiods in the same first manner as that during the first and secondtime periods; and control the secondary RF generator to output thesecondary RF signal that pulses between the off and secondary frequencylevels during the additional time periods in the same second manner asthat during the first and second time periods; and a memory devicecoupled to the processor.
 2. The controller of claim 1, wherein thefirst time period and the second time period occur during a cycle of adigital pulsed signal, wherein the primary frequency level is a firstoperational frequency set point of the primary RF generator, and thesecondary frequency level is a second operational frequency set point ofthe secondary RF generator.
 3. The controller of claim 1, wherein theprimary RF generator is turned off during the second time period inwhich the primary RF generator has the off frequency level, and thesecondary RF generator is turned off during the first time period inwhich the secondary RF generator has the off frequency level.
 4. Thecontroller of claim 1, wherein each of the additional time periods isequal to a sum of the first and second time periods.
 5. The controllerof claim 1, wherein the upper electrode is a transformer coupled plasma(TCP) coil of the plasma chamber, wherein the primary RF generator isconfigured to operate at a lower frequency compared to the secondary RFgenerator.
 6. The controller of claim 1, wherein the processor isconfigured to send the primary frequency level, the off frequency level,the first time period, and the second time period to a digital signalprocessor (DSP) of the primary RF generator to control the primary RFgenerator to output the primary RF signal.
 7. The controller of claim 1,wherein the processor is configured to send the secondary frequencylevel, the off frequency level, the first time period, and the secondtime period to a digital signal processor (DSP) of the secondary RFgenerator to control the secondary RF generator to output the secondaryRF signal.
 8. A plasma system comprising: a primary radio frequency (RF)generator configured to generate a primary RF signal; a secondary RFgenerator configured to generate a secondary RF signal; an impedancematching network coupled to the primary and secondary RF generators toreceive the primary and secondary RF signals to output a modified RFsignal, wherein the modified RF signal is output based on the primaryand secondary RF signals; a plasma chamber having an upper electrodecoupled to the impedance matching network, wherein the upper electrodeis configured to receive the modified RF signal to modify an impedanceof plasma within the plasma chamber; and a host computer coupled to theprimary and secondary RF generators, wherein the host computer isconfigured to: control the primary RF generator to pulse the primary RFsignal in a first manner between a primary frequency level during afirst time period and an off frequency level during a second timeperiod; control the secondary RF generator to pulse the secondary RFsignal in a second manner between the off frequency level during thefirst time period and a secondary frequency level during the second timeperiod; control the primary RF generator to pulse the primary RF signalbetween the primary and off frequency levels during additional timeperiods in the same first manner as that during the first and secondtime periods; and control the secondary RF generator to pulse thesecondary RF signal between the off and secondary frequency levelsduring the additional time periods in the same second manner as thatduring the first and second time periods.
 9. The plasma system of claim8, wherein the first time period and the second time period occur duringa cycle of a digital pulsed signal, wherein the primary frequency levelis a first operational frequency set point of the primary RF generator,and the secondary frequency level is a second operational frequency setpoint of the secondary RF generator.
 10. The plasma system of claim 8,wherein the primary RF generator is turned off during the second timeperiod in which the primary RF generator has the off frequency level,and the secondary RF generator is turned off during the first timeperiod in which the secondary RF generator has the off frequency level.11. The plasma system of claim 8, wherein each of the additional timeperiods is equal to a sum of the first and second time periods.
 12. Theplasma system of claim 8, wherein the upper electrode is a transformercoupled plasma (TCP) coil of the plasma chamber, wherein the primary RFgenerator is configured to operate at a lower frequency compared to thesecondary RF generator.
 13. The plasma system of claim 8, wherein theprimary RF generator includes a digital signal processor (DSP) coupledto the host computer, wherein the host computer is configured to sendthe primary frequency level, the off frequency level, the first timeperiod, and the second time period to the DSP of the primary RFgenerator to control the primary RF generator to pulse the primary RFsignal.
 14. The plasma system of claim 8, wherein the secondary RFgenerator includes a digital signal processor (DSP) coupled to the hostcomputer, wherein the host computer is configured to send the secondaryfrequency level, the off frequency level, the first time period, and thesecond time period to the DSP of the secondary RF generator to controlthe secondary RF generator to pulse the secondary RF signal.
 15. Amethod comprising: controlling a primary radio frequency (RF) generatorto pulse a primary RF signal in a first manner between a primaryfrequency level during a first time period and an off frequency levelduring a second time period; controlling a secondary RF generator topulse a secondary RF signal in a second manner between the off frequencylevel during the first time period and a secondary frequency levelduring the second time period, wherein the primary and secondary RFgenerators are coupled to an upper electrode of a plasma chamber via animpedance matching network; controlling the primary RF generator topulse the primary RF signal between the primary and off frequency levelsduring additional time periods in the same first manner as that duringthe first and second time periods; and controlling the secondary RFgenerator to pulse the secondary RF signal between the off and secondaryfrequency levels during the additional time periods in the same secondmanner as that during the first and second time periods.
 16. The methodof claim 15, wherein the first time period and the second time periodoccur during a cycle of a digital pulsed signal, wherein the primaryfrequency level is a first operational frequency set point of theprimary RF generator, and the secondary frequency level is a secondoperational frequency set point of the secondary RF generator.
 17. Themethod of claim 15, wherein the primary RF generator is turned offduring the second time period in which the primary RF generator has theoff frequency level, and the secondary RF generator is turned off duringthe first time period in which the secondary RF generator has the offfrequency level.
 18. The method of claim 15, wherein each of theadditional time periods is equal to a sum of the first and second timeperiods.
 19. The method of claim 15, wherein the upper electrode is atransformer coupled plasma (TCP) coil of the plasma chamber, wherein theprimary RF generator operates at a lower frequency compared to thesecondary RF generator.
 20. The method of claim 15, wherein saidcontrolling the primary RF generator to pulse the primary RF signalincludes sending the primary frequency level, the off frequency level,the first time period, and the second time period to a digital signalprocessor (DSP) of the primary RF generator, wherein said controllingthe secondary RF generator to pulse the secondary RF signal includessending the secondary frequency level, the off frequency level, thefirst time period, and the second time period to a DSP of the secondaryRF generator.